Director Technical and Supply Chain Operations
Wilshire Labs Pvt Limited
Total years of experience :29 years, 6 Months
Responsible for Manufacturing Plants of Pharmaceutical and Nutraceutical's
.Production
.Engineering, Maintenance, Projects
.Quality Control & Assurance
.Product Development
. Supply Chain
...Materials and Production Planning
...Procurement and Materials Management
...Inventory and Warehouse Management
Head of Operations -Pharmaceuticals/Nutraceuticals
o Heading Plant Operations of 3 ICI Sites - Hawksbay Plant (xWyeth), Hattar Plant (xCirin), and Nutraceutical Plant
o All the plants are ISO9001:2008/2015 certified. Nutraceutical is certified in Nov 2017. Wyeth plant was WHO certified.
o Plants have capabilities to produce tablets, capsules, liquid, liquid suspensions, powder suspensions, softgels, powder injections, liquid injections, and sachets, cumulatively 80m packs per annum and plans are made and in place to double them by 20-21.
o Managing dedicated therapeutic areas for Cephalosporin, Penicillin, Carbapenem, Steroids, Psychotropic, and AntiTB besides general oral dosage forms of tablets, capsules, liquids and sachets.
o Handling the portfolios of 80+ Pharmaceutical and Nutraceutical brands.
o Plant Operation includes Production, Planning, Engineering/Maintenance, Quality Operations, Projects, Administration/IR, HSE, Stores.
o Responsible for Operations of ICI own, Toll manufactured by ICI and Toll manufactured for ICI products
o Aspiring an annual delivery plan of 7+bnPKR (80m packs) with a vision to double by 2020-21.
o Leading a team of 500+ members comprising management, contractual and unionized staff.
o Custodian of 650+ mPKR budgeted factory operating cost.
o Led smooth transition of Wyeth to ICI and excelled the past production records.
o Delivered double than the budgeted numbers of Nutraceutical Products.
o Revamping Hattar Cirin Plant while in operation to make more GMP Compliant.
o Established next 3 years Production, Capacity, FPC and Headcount plans.
o Providing active indirect support to Business Development, Product Development, Supply Chain and Materials Management, by virtue of past experience.
Heading Plant Production Team responsible for manufacturing of Pharmaceutical and Cephalosporin Oral Dosage and Sterile Products.
o ISO 9001-2008 and HACCP certified facility meant for tablet, capsule, powder sachet, oral liquid, powder suspension, sterile powder vials, sterile liquid ampoules manufacturing and packaging facilities operating in 2 shifts.
o Heading a team of 12 Management (Senior manager directly to officer indirectly) and 360 staff persons and addressing/imparting their annual goals, performance and training needs.
o Responsibilities include man, material and machine management of 40m Packs supporting 5b PKR of company sales.
o Responsibilities include production planning, manufacturing and packing of sterile cephalosporin and oral dosage pharma products.
o Achievement of breaking all time 12 year record of production and improve it further by 4.4 m Packs in a month.
o Active member of Project Team heading construction and installation of Nutraceutical Plant, expansion of Pharmaceutical plant, installation of new latest machine and technologies.
o Active member and leading production team to implement WHO and PICS requirement at Production facilities and adopting practice and systems compliant to them.
o Guiding Engineering, Quality, HSE, Supply Chain, BD, Regulatory and HR team, by virtue of past experience, in adopting best practices and bringing efficiency in their performance.
Responsible for all supply chain activities- planning, procurement, warehousing, logisitics and distribution.
• Procurement :
o Materials buying from supplier base of 100+ vendors and inventory management of worth 3.5bn PKR.
o Incoming materials planning, scheduling, pricing, ordering, expedition, storage, approval, & issuance.
o Procurement of packaging, engineering, non-inventory, & all promotional materials.
• Planning :
o Custodian of S&OP process.
o Conducting MRP, MPS, and Logistics for 2 plants having the capacity of 250 tons per day.
o Plan made-to-order and made-for-stock for export to 14+ countries.
o Replenish all 7 distribution centres and 2 transit warehouses.
• Warehousing of Incoming Materials, FG and Distribution Centres:
o Maintain the inventory with compliance to company policies such as FIFO, OFR, and dispatch within agreed lead time to distributors.
o Managing the 9 warehouses and stores across country and 2 3P distribution warehouses.
• Logistics:
o Responsibility includes managing the logistics of raw, packaging, FG and promotional materials to both plants and 7 distribution warehouses.
o Dispatches from Distribution warehouses to the base of 600+ distributors across the country.
• Revamped the entire supply chain structure, individual’s responsibilities and procedures to align them as per future business needs.
• Have ensured Business Continuity Plans by employing alternate source for maximum services and all incoming materials.
• Quality Assurance:
o Task was given to lead QA and QMR to revamp the Quality function.
o Establish Packaging Labs at both manufacturing sites. Procedures, specifications, and work instructions are revised and implemented.
o All the resources - technical experts, manpower and equipment are identified and employed.
o Processes and Team roles are reviewed and established with defined Business KPIs. Dashboards in BOBJ are defined and established for BI.
o Led the New Packaging Development initiatives from concepts to execution, covering packaging design, development at vendor, production trials, transit test at logistic ends and henceforth.
Responsible for New Products Development from concept to launch.
• Identification, evaluation and selection of potential new products and projects for National and International Markets. Successfully led the launch of Biotech products (Interferon, Insulins), Antibiotics, anti-angina, anti-convulsant, anti-Hypertensive, anti-diabetic, anti-retroviral, anti-osteoporotic, anti-rheumatic, and other therapeutic solutions building strong 3-year pipeline.
• Responsible for delivering all local New Products / Existing Products projects which includes complete product development coordination, technology transfer ranging from raws, packaging, manufacturing, analytical methods and logistics coordination.
• Worked in close liaison with International R&D teams to monitor each stage of product development.
• Conducting all packaging development activities considering and ensuring all the regulatory, aesthetic, quality and functional aspects of packaging.
• Developing and auditing toll facilities to develop and launch new products and maintaining relationships to sustain the quality and services standards.
• Identifying and commercialize licensing activities to introduce novice technologies in the market.
• Ensuring secured launches in terms of Intellectual Property Rights (IPR) -Trademarks, Patents, Copyrights and cases related to IPR. Managing all activities related to them encompassing from documentation to strategic decisions.
• Coordinating regulatory and managing legal affairs
• Carrying out projects to enhance supply chain and gross margin improvement efficiencies including the revisions of BOMs, Process Routing and Reduction of Mudas from processes such as wastages of materials.
• These projects contributed around 20% of business NR of ~ 9bn PKR Company. Leading a team of dynamic professionals and managing the budget of ~25m PKR.
Supply Projects Manager, QMR and Quality Manager
• Deliverance of all NPD/EPD, Gross Margin Improvement projects including complete technology transfer from raw materials, packaging, production & warehousing coordination
• Execution of complete Supply Chain Management cycle from identification of new products to feasibility, development of infra-structure, lot size determination, system plug-in, planning, production, logistics, distribution ending at post launch performance reviews.
• Complete development of packaging locally. Has delivered break through packaging solution to extend brands to drive cost down quite few times to lead business regionally and globally.
• Responsible for toll/contract manufacturers’ installations and developing complete infrastructure sufficient for three years forecasted quantities.
• The important launches during this period are Strepsils, Harpic, Veet, Gaviscon, Dettol MPC, Dettol Soap, Robin Liquid Blue, Mortein LEDs, and Robin Liquid.
• (Additional Responsibility)
o Quality Management Representative
Established, Developed, Implemented, Certified and Maintained the RB QMS which is based on PDCA cycle and Acquired ISO 9001:2000 certifications from UKAS without any non-conformance, resulted in waiver of 6−month surveillance audit and extended to eleven month surveillance visit.
As a QMR, conducted Audits, Monitored KPIs and coordinated Management Reviews to apprise the top management of organization performance.
o Quality Manager
Responsible for leading the Quality Control and Quality Assurance Team to deliver on−time and upto mark quality services.
Effective QA by inspection, validation, KPI monitoring and auditing, executing core system procedures of Change Management, NCR handling, Customer complaints and others.
Similarly, lead the qualified team of Chemists, Pharmacists and Microbiologist to provide timely analytical support to raw, packaging, FG release with precisely calibrated latest equipment and well maintained inventories of reagents/ chemicals.
Supply Packaging Manager
As a function of Supply Chain, led the Supply Packaging Function, responsible for
• Established a strong lab and quality system to handle the development & analysis of all packaging materials, handled 110+ products and ~500 components.
• Established the strong analytical systems, specifications, sampling plans (MIL standard), AQL levels, release criteria, packaging development and monitoring criteria.
• Qualified Packaging Suppliers. Establish a unique supplier qualification program which later regionally and globally acclaimed (within RB) and conducted audits. Qualified 80%of supplier base resulted in durable quality packaging base with drastic reduction in quality issues and ultimately saved the time from spending non−value adding activities. Vendor base of Paper & Board, Plastic, Flexibles, Glass, Tin, are conducted and certified on a peculiar ratings.
• Transformed packaging formats to more economical, efficient and effective solutions. Encompassing brands as Dettol, Mortein, Robin, Veet, Harpic, Gaviscon, Disprin, Pouches, etc. Covering formats such as cartons, shippers, labels. plastic bottles, glass bottles, tins, flexible pouches, etc.
• This position reports to matrix of National and Regional Managements. For all technical aspects, guidelines, procedures and policies reported to Regional Head Supply Packaging.
GMP Manager
• Responsible for implementing QA Systems and Good Manufacturing Practices at 5 manufacturing sites of Company.
• For two Pharma sites implemented Drug Act 1976 Schedule Bs requirement. For rest of the sites, developed and implemented Quality systems. This activity included practices of KPI Monitoring, Auditing, Documentation, Validation and Qualification, Calibration, Training, Lab Management, and Hygiene.
• Rolled out GMP and implement QA systems at other 3 units of Reckitt business of Household Cleaning and Polishes, Pest control and Ultra-marine products.
All aspects of Quality Assurance and Quality Control including GMP compliance and training
extensive work experience in sterile liquid, powder and cream production. quality assurance and headed GMP comliance, quality assurance and audit function.
First Class First Position