Production manager Cheese
almarai
Total years of experience :8 years, 0 Months
Job Responsibilities: Nov 2012- till date as Production manager Cheese
➢ Ensuring Health and Safety standards are met in the department: * Ensuring the production department working in a safe environment;
* Effective Risk assessments are carried out for the complete area and equipments along with timely completion of corrective actions
* Zero accidents
➢ Ensuring products produced met the required Quality standards: * Ensuring right first time release of the product
* Ensuring zero dumped material
* Targeting zero tolerance for the non conformance product and Less than budgeted CPM
➢ Ensuring meeting the Customer demand: * Monitor stock levels daily/weekly to ensure market is supplied but not over stocked
* Understanding of potential market sales verses capacity and address capacity constraints to meet the demand
* Optimize production plan to improve OEE and deliver production plan requirements
➢ Actively involved in implementation of lean management initiatives to arrest the Cost: * Ensuring LIP for ingredients, packaging well under budget as well as labor cost under control
* Carry out loss and waste analysis, identify top improvement projects and implement
* Identify and address top LIP issues using structured problem solving tools
➢ Leading the effective utilization of tools to enhance Productivity
* Productivity Improvements using DMAIC and A3 approach.
* Effective use of 5 whys to drive down number of issues
* Put in place plan to progressively increase OEE by 5% every year
➢ Leading the People Development plan within the department
* Hold effective induction programmes for all new starts
* Introduce daily line meeting with operatives to review line performance and nurture engagement
* Review man power utilization across the whole line and redefine/reduce number of roles to improve utilization
* Cross train staff along the line to improve operator flexibility
* Draw up and implement an effective localization programme to deliver company targets
January 2012- Nov 2012 as Senior Team Manager Operations Excellence
➢ Actively involved in implementation of Lean Management initiatives in cheese plant
➢ Leading/facilitating the Loss and Waste exercise in order to identify the waste in the process, carrying out speed profile study to identify bottlenecks, value the opportunities followed by prioritizing and action plan to reduce the losses
➢ Leading the cheese plant SOP development project activity to have ease in understanding the process for any new employees in the system
➢ Involved in Target savings activities for cheese plant
➢ Leading the CIP optimization activities in cheese plant viz. CIP time reduction, CIP regime optimization, chemical concentration reduction
➢ Implementation of process confirmation checklist and control charts in order to have more focus on the operation by the manufacturing team
➢ Actively involved in the drain losses reduction projects in order to reduce the waste in drain thereby reducing load on ETP
➢ Involved in the scoping as well as commissioning of the new projects (RCC up-gradation project)
➢ Involve in optimizing the process as well as increase in the current production volume by optimizing the production plan
➢ Leading/facilitating implementation of structured problem solving exercise (PPS:A3, DMAIC, Fishbone diagram, Brainstorming etc.) so that the root cause is identified and proper corrective and preventive action implemented in place by means of DMAIC, fishbone diagram, brainstorming tools
July 2011- Dec 2011 as Technical QA Sr. Team Manager
➢ Management of new/improvement projects towards timely, effective and efficient implementation and commissioning of equipment / process and product
* Active involvement in installation and commissioning of new machines and process
* Preparation of new proposal for improving the existing process and product as well as for expansion
* Preparation of the scope document
* Involved in HARA (Hazard analysis and Risk assessment) for the project
* Project installation and commissioning
* Coordination with the other department during installation and commissioning
* Responsible for successful completion of product trials and commercial production on the new equipment
* Responsible for 100% successful completion of the project
➢ Involved in the commissioning and successful launch of jar cheese variant in the market
➢ Optimization of the production parameters to have consistent quality products produced across all production lines
➢ Ensuring no impact on product quality post CIP optimization
➢ Optimization of ingredient usage to have efficient use of ingredients towards achieving targeted specifications
➢ Improvement in LIPs to targeted levels
➢ Preparation and maintenance of guiding rules for production planning, processing and cleaning conditions
➢ Ensuring consistent production run with maximum efficiencies
➢ Working with Continual Improvement team for product NCN's, product complaints, root cause investigations and corrective actions
➢ Managing Control / Ensuring hassle free operation of UHT plant, vacutherms, Corazza, Trepko, Weigh pack jar filling and FMC can filling lines
➢ Involve in HACCP study of cheese products and services
May 2010- June 2011 as Team Manager in Cheese processing filling section
➢ Health and Safety: Ensuring health and safety requirements are met by: * Carry out an area induction with each new employee or contractor
* Maintain high standard of safety & hygiene on all machine and equipments
* Perform Risk assessments for the critical operation and fix the hazard
* Ensure that correct PPE is issued to all staff and used correctly by all staff on the line and that all H&S procedures are being followed by operators
* Targeting zero accidents within the department
➢ Quality & hygiene: Ensuring the high quality and GMP standards are met by: * Participate in the weekly GMP audit
* Think Food safety at all times & challenge team continually on raising standards.
* Segregate non conforming products. Carry out 5 Why to identify route cause/corrective actions.
* Complete NCNs based on 5 why approach.
* Maintain records as per SOP by regular check on operator logs
* Ensure that all processes & activities are proceduralised in quality system
* Conduct quality audit according to agreed schedule (I'm a certified auditor)
* Ensure products are manufactured according to HACCP principles
➢ Productivity: * Calculate the OEE accurately for each line updating the OEE report with accurate reasons for OEE loss.
* Ensure EMD and automation are informed immediately of breakdowns/potential breakdowns/change overs. Assess how the impact of the breakdown can be minimized e.g. switching to another filler.
* Maximizing utilization of available resources, investigate and implement methods of improving losses
* Process trouble shooting expertise
* To optimize product quality and ensure that product meets required specifications and legal requirements.
➢ Sustainability / Cost
* Daily/weekly verification checks on scales, load cells and flow meters
* Investigate LIP variances for Ingredients and packaging and implement initiatives to address these variances
* Monitor where product/ingredients are being lost to drain and address these issues
* Monitor and control product give away (Filling)
➢ People: * Controlling the multi task work force & ensuring the line is effectively resourced with the proper skilled level
* Managing all necessary on the job trainings (OJT) to the staff members.
* Assist subordinates (TL/DT/LPO) to carry out their duties effectively.
* Assist production manager in the assessment and development of the staff and identify the training needs to provide adequate succession planning
April 2008- April 2010 as Dairy technologist in Cheese processing filling section
➢ Managing the multinational work force.
➢ Involved in optimizing the productivity & machine utilization to maximize overall profitability of the Department and as a whole to the Organization.
➢ Maintain record keeping as per the standard operating procedures
➢ Main focus on service levels to internal customers
➢ To optimize yield and minimize the loss in process or wastage of the product.
➢ Efficiently managing the KPI's and Documentary required for safe and Quality Product.
B) AMUL-SAGAR DAIRY, District Co-operative Milk Producers union Ltd, India
Duration: 1 October 2005 -7 April 2008
Designation: Jr. Production officer
AMUL is also the largest exporter of dairy products in the country. AMUL is available today in over 40 countries of the world. AMUL is exporting a wide variety of products which include Whole and Skimmed Milk Powder, Clarified Butter (Ghee) and Sweeten condensed milk. The major markets are USA, West Indies, and countries in Africa, the Gulf Region, and \[SAARC\], Singapore, The Philippines, Thailand, Japan and China.
Job Responsibilities: ➢ Daily & Monthly Production Planning & successful Execution.
➢ Handling of product complaints
➢ Achieving the production targets within time and cost parameters.
➢ Managing 5M's & minimizing losses in production, utilizing Optimum resources for Maximum output.
➢ Inventory Management
➢ Implementing ISO, HACCP, GMP and SOP for maintaining quality standards.
➢ Minimizing performance bottlenecks for achieving high productivity with minimum consumption of material & machine and monitoring expenses.
➢ Identify problems before they affect production deadlines and solve them within the stipulated time frame keeping in mind the perishable nature of the Product.
MBA (PGDM) IN SALES & MARKETING - 2006- 2008