Lead Auditor
TUV,
Total years of experience :32 years, 1 Months
QMS / H&EMS Auditor / Consultant / Trainer April 2010 - Till Date
FAHSS/TUV (Germany)
• Expert in preparing, implementing, auditing and training for projects related with ISO 9001, 14001, OHSAS 18001.
• Completed around 300 Certification audits and approx. 50 consulting projects for the certifications in ISO 9001. 14001 and OHSAS 18001
• Presently working on Integrated Management projects also
• Working in the Above mentioned company, throughout KSA
• Having a valid driving license for KSA and all GCC countries.
• Special expertise in planning and implementing of plant layout, Re-engineering, Project Planning.
• Line balancing, Production and Material Planning, Value Stream Mapping
• Expert in Re-Engineering projects, specially related with industrial setup.
Lead Audor and trainer in the field of ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, OHSAS 18001:2007
SHEQ Manager (South Region) April 2009 - August 2009
Al Gihaz Co. Ltd. (KSA)
• Development of procedures and other required documents needed in an Integrated SHEQ Management System.
• Implementation of SHEQ Management System.at all sites and stations, in accordance with the documented procedures.
• Planning, implementation and reporting of scheduled Audits of all sites and stations.
• Planning and executing training of personnel at all levels regarding the documented procedures and principles of Safety, Health and Environmment.
• Special training about Quality Assurance on corporate basis.
• Preparing, follow-up and reporting of all Non Conforming Reports.
• Participating in Management Review meetings, for coordination with the management for the solution of problems.
• Prepared the "Projects Quality Plan" and "Corporate Safety Plan", for the first time, which was approved by the management.
• Submitted the above mentioned important documents for tendering purposes for some very high prestige projects where these were accepted.
• Arranged training for "Safety Officers" at all projects sites.
• Established and reviewed the requirements of PPEs for each project/plant site and coordinated with top management for ensuring their availability.
• Developed and improved a system for initiating and reviewing the reports of all safety related incidents, near misses, or accidents for the purpose of recurrence prevention.
• Deputed Safety Officers at different sites and arranged a network of safety related information.
• Reviewed the existing Integrated SHEQ documents and suggested important improvements.
• Arranged Inernal Audit of a company factory, arranged improvements and achieved success in Surviellance Audit.
GENERAL MANAGER PLANT Jan 2007 - March 2009
Ghandhara Nissan Ltd, Karachi
• Initiated and implemented projects for new products development / improvements and plant improvement with highest priority on quality, and customer satisfaction.
• Directly controlling the performance of two warehouses in the plant.
• Accountable for the plant activities including all SHEQ related targets, quality, designing, costing, feasibility and implementation of new machinery & quality projects.
• Plan and implement training of the employees for the development of suitable organizational culture and improve their effectiveness.
• Accountable for establishing standard operation for each production activity and carry out continuous improvements by gradually reducing the defect level.
• Making continuous improvements in the integrated SHEQ management plans by suggestingband improving the existing practices.
• Introduced new plant / engineering management tools based on the best management practices using the concepts of Man-Power control, and Recording/Analysing Downtime and its reasons. This data was used for corrective and preventive actions.
• Planned and implemented the start of SHEQ management system, by making improvements in Safety of the plant operations and important facilities, which were initially lacking.
• Introduced and implemented "Kaizen" methodology by initiating with" Suggestion Scheme".
• Implemented a stage wise Quality inspection system in the main assembly line, thereby controlling the quality problems. Achieved a reduction of problems by 30%.
• Calclated the actual Tact time of assembly line and implemented a number of big as well as small improvements. Tact Time was reduced from 50 minutes to 40 minutes.
• Based on the current status of Tact Time and Time and Motion study, developed a plan for further improvement of quality and adding flexibility in the system, by means of enhancement in the plant layout/facilities. This will increase the output by more than 60 %.
GENERAL MANAGER OPERATIONS Apr 2006 - Jan 2007
Precision Rubber Industries (pvt.) Ltd, Karachi
(A company of National Foods Group)
• Taken on board as a consultant to work on their "Plant Re-Engineering Project" based on the best management practices and revamp the factory in order to improve productivity, quality and profitability of the organization, by designing a revised plant layout after exercising the use of Process Mapping and Time and Motion studies.
• Establishing a state of the art laboratory to be used in preparation of rubber components for textile industry, improving the existing ISO 9000 Quality Management System.
• Plan, implement, and improve a Production Planning and Control Department, which will work in coordination with the existing ERP system.
• Liaise with the marketing department for smooth supply of product to the customer.
• Plan and implement training of the employees for the development and improving their effectiveness.
Key Achievemnets: • Conducted complete survey and technical audit of the existing plant for finding the sources of wastages and other harmful factors like safety and health risks. Prepared detailed plan for the complete Re-Engineering of the production process. Conducted Process Mapping for better productivity.
• Implemented the above mentioned plan, which included improvements in steam generation and utilization, new trimming and finishing facility, exhaust system for solid fine rubber particles, extraordinary improvements in ventilation of the plant.
• Working in parallel to the Productivity/Quality improvement project, carried out Plant and Warehouse Safety Survey and made considerable improvements in the status.
• Initiated a newly installed Rubber Testing lab. Trained the staff for the operation of lab machines. Instrumemtal in the implementation of SPC and implementation of a suitable system of Production Planning and Control, integrating with computers for smooth production flow.
MANAGER PRODUCTION PLANNING, MATERIALS AND LOGISTICS Jul 2000 - Jan 2002
Transpak Corporation Ltd. (Dawlance Group), Karachi
• Charged with the planning / procurement of the required raw material and packing material, in accordance with Production Plan, supervising the staff of Production & Maintenance department.
• Accountable for the planning and implementation for Quality Assurance and Control activities, by guiding the functional in charges. Creating a Management System, in accordance with ISO 9000, and ISO 14000 guidelines for the targeted certification in near future.
• Ensuring smooth interface with the Safety Team, actively assisting in the documentation of procedures related with Safety and Health and providing guidance and leadership for the development of Safety programs, plan their implementation and monitor the performance.
• Gained training in ISO 9000 related programmes as well as Management Improvement and Planning and successfully introduced the use of Statistical Softwares.
• Designed and implemented a complete Production Planning and Control System. This improvement resulted in increase in productivity, Control on frequent "Stock Out" situation in the store. In general a considerable improvement in productivity and quality was achieved
• Completely changed the vendors by gradual shift towards better quality and low cost sources. All these improvements resulted in a considerable cost saving. Directly supervised the production activity
• Implemented a number of improvements in the packaging design of the products reviews and other corrective actions for over-all oerganizational improvement.
MANAGER QUALITY ASSURANCE / MAINTENANCE & QMR Feb 1999 - July 2000
Adamjee Engineering ( Pvt.) Ltd
• Planning, implementation and monitoring of quality management system for all stages of production and vendors / suppliers.
• Finalizing the documentation work of Quality Manual for achieving ISO 9001.
• Planning / implementation for Internal Audit as Management Representative.
• Planning and participation in TQM activities
• Major responsibilities, includes the set up of a new Quality Assurance department and the preparation for ISO 9002.
• Setting up of Incoming Material Inspection system.
• Designing, development and implementation of Heat treatment Oil Quenching system, making use of locally available machinery. The system is being used for hardening process of Concrete Nails.
• Introduced and installed a completely revised and modernised Quality Assurance procedure in all activities which improved the product quality
• First time introduced and arranged complete calibration of measuring instruments/tools for the whole company.
• Prepared Technical Specifications of different types of fasteners, to compare with British and German Standards. Where needed, prepared local specification based on company's own experience and technology available within the country.
• Major role as QMR of the company, in documenting, implementing, auditing, and finally achieving certification of ISO 9000.
• Running the complete activity of Quality Management System as QMR with complete success and improvement of quality culture.
• Introduced & implemented a computerised "Statistcal Process Control System", by using a world renowned software "Statistica"
• Trained the staff on the above mentioned SPC.
MANAGER QUALITY ASSURANCE May 94 - Dec 1998
Hinopak Motors Ltd
• Planning and participation in TQM activities arranged by Quality Assurance Department.
• Planning and implementation of complete Quality Assurance activities including Incoming Material, inprocess and final Q/A
• Training a team of Quality Assurance executives to participate in activities related with preparation for third party audit by foreign auditors for ISO 9001.
• Planning, organizing, and monitoring of Corrective and Preventive actions, e.g. response on Customer Complaints, In-house Quality Problems, Design Quality Improvements etc.
• Planning and implementing programs on Quality Improvement through the education of vendors / suppliers by arranging periodic visits.
• Planning & implementation of quality management system for all stages of production and vendors / suppliers.
• Participation in documentation work for quality manual for achieving ISO 9001.
♦ Achieved a considerable decrease in customer complaintsApprox. 35 % in five years.
♦ Major participation in documenting, implementing, auditing, and finally achieving certification of ISO 9000.
♦ Planning and implementation for all stages of development and approval of components, prepared by local companies / vendors, under the strict guidelines of Japanese principals (HINO)
♦ Preparing acceptance standards of bus body components / material, based on practical observations, or SAE / JIS standards.
♦ Planning and implementation for testing of material / components by developing in-house facilities.
♦ Development /improvement of quality culture throughout the organization to prepare for TQM implementation
♦ Planned, implemented and Participated in Quality Circle Program for "Kaizen" activities. Secured 2nd. position in the presentation of project.
• Design & Development Engineer, Hinopak Motors Ltd, Karachi, Oct 1989 - May 1994
• Product Manager Packaging Machines, Integrated Management Services (Pvt.) Ltd, Karachi, Jun 1987 - Oct 1989
MBA - MARKETING, Institute of Business Administration, IBA, Karachi, 1995
B.E - MECHANICAL ENGINEERING, NED University of Engineering and Technology, 1985