Ibad Ali

• BRC & AIB Compliance
• Established Standard Operating Procedure (SOP)
• Evaluating Raw materials (Run ability & Specifications)
• Maintaining MSDS and TDS
• Raw material & Sami Finished Product Inventory
• Implementing standard raw materials for 78 different products
• Maintaining OEE
• Yield calculations

• Implemented the SAP MM (Material Management) module across the production unit and trained over 12 supervisors to ensure
efficient usage and accurate production data entry.
• Resolved oil condensation issues on the final film product by identifying root causes and applying targeted process
improvements, improving product quality and reducing customer complaints.
• Standardized process protocols, raw material specifications, and product quality parameters to maintain consistent production
output and ensure compliance with industry and regulatory standards.
• Led the implementation of BRC standards and coordinated 3 successful AIB audits, achieving food-grade manufacturing
compliance and strengthening customer trust.
• Accurately performed manufacturing yield calculations and ensured real-time SAP entries for over 300 production batches,
improving transparency and traceability.
• Handled production planning, inventory control, and maintenance scheduling, which resulted in zero unplanned downtime over
a 6-month period.
• Spearheaded continuous process improvement and quality control initiatives, reducing rework and scrap generation through
structured root cause analysis and corrective actions.
• Maintained detailed documentation for all processes, ensured workplace safety compliance, and monitored the performance of
over 25 raw material SKUs and finished goods

Up gradation of existing 3 layer BOPP line to 5 layer BOPP line.
 Established project schedules and ensured that milestones were met during each phase.
 Job safety analysis of 5 layer up gradation project.
 Implementation of pleated filter for main extruder.
 Calibration of rotary feeders for raw material with different gravity. (implemented system)
 Implemented scheduled maintenance, retooling production status sheets .
 Applied lean principles to improve workflow and quality and reduce waste. (5S, Kaizen)
 Prepared and maintained production reports and personnel records. (SAP)
 Maximized resource utilization and achieved production targets by managing day-to-day usage of department resources.
 Set up of machine as per production plan and convey set up requirements to operators. Review, trace, control and minimize wastages. Machine troubleshooting.
 Root cause analysis of all operational and quality related issues in a way that they are not repeated, the main point is to document the root cause and communicate down the level.
 Reviewed processes, identifying areas that required improvement.
 Developed manufacturing processes that were robust yet simple to perform.
 Coached newly hired employees and interns while observing progress and delegating tasks.

• Successfully led the upgrade of the Brückner BOPP production line from a 3-layer to a 5-layer setup by performing detailed Job
Hazard Analysis (JHA), ensuring smooth implementation and zero safety incidents.
• Conducted calibration of rotary feeders, resulting in improved material dosing accuracy and consistent product quality across
over 1, 200 production cycles.
• Implemented Total Productive Maintenance (TPM) strategies, reducing unplanned equipment failures and promoting a
proactive maintenance culture across the plant.
• Spearheaded the pleated filter project, managing its design and integration into operations, leading to enhanced filtration
efficiency and smoother production flow.
• Acted as the SAP custodian, ensuring system accuracy, managing data integrity, and training 15+ new employees on SAP
functionalities and production workflows.
• Initiated and led multiple process optimization projects that resulted in a reduction of raw material waste by over 2, 000 kg
annually and boosted overall production efficiency.
• Applied advanced problem-solving and troubleshooting skills to resolve critical process disruptions, maintaining continuous
operations during more than 200 production shifts.
• Ensured operational excellence by driving continuous improvement initiatives, aligning production goals with safety, quality,
and efficiency benchmarks.