Operations Manager
Arabian Plastics industrial Co Ltd - Balubaid Group KSA
مجموع سنوات الخبرة :11 years, 11 أشهر
Manufacturer of Injection, Blow Molding, Thermo Forming Blown Film Products)
Location: JEDDAH, Kingdom of Saudi Arabia
Products Manufactured: Injection Molded Product: Crates, Pails, and Micro Wave Containers, industrial and domestic items Blow Molding: 250ml to 4 Litre Bottles and up to 30 Litre Jerry Cans Blown Film Products: multipurpose Shopping bags, Trash bags, e commerce bags Slitted rolls and Heavy duty Film Rolls etc Thermo forming : All Kind of Food disposable Containers, beverages cups, Trays etc
Major Customers: Al Marai, Nadec, Panda, Balubaid Automotive Nahdi, Al Soraiya Carpet, Castrol, Centre point, TOTAL, Sealy, Mobil, APLG, Lulu, City Max etc
Key Responsibility & Accomplishments
Key Responsibility:
Responsible For Entire Manufacturing Operations (from Raw Materials to Final Finished Product) - Production Planning and
Execution, Ensuring On time Delivery to Customers, Machine Maintenance and enhancement and Preventive maintenance and Spare parts and accessories management, Tool Room Management Quality control and assurance, Raw material and Finished goods Ware house, workforce employee management and manpower planning and training, Business Development Activities in coordination with Sales & Marketing Teams & product developments are in direct Responsibility and closely associated with other Departments i.e Sales & Marketing, Finance, Procurement and Logistics Dept, HR & personal Departments and Supply Chain Departments
Key Accomplishments:
Techno -Commercial Operations of manufacturing multiple plastic products worth 150 Million SAR / Annum turnover
•Excessive Product Weight Reduction and During Hike of Raw Material Price introduced various blends of Raw materials to save the costs
•Overall cost reduction projects implementation and achieved reasonable cost reduction
•Enhanced the machineries and equipment’s to reach optimum level output
•Controlled cycle time of each machine and reduced the down time of each machines
•Involved and lead for new machinery installation 1000 ton & 350 Tons Injection molding machines and SIKA Blow molding machine
•Suggested for auto robotic functions in injection and blow molding and for high efficiency and reduced manpower
•Reviewed the business performance and allocate the percentage of
•Initiating steps for continuous improvement, reducing costs and lead times, optimizing performance and delivering innovative solutions at every opportunity.
•In coordination with Sales team drawn up the right delivery schedules and ensured delivered on committed dates
•During New products enquiry and implemented the possible modification to produce in-house
•Drawn up various product mix capacity and advice sales for allocation to meet up market demands
•Review the manufacturing cost and Reduced in possible areas
•Optimized the Product Quality in every stage of manufacturing process
•Implementing the art of monitoring production output and costs and adjusting processes and resources to minimize costs. Implement various techniques like Value Engineering and Value Analysis, Total Productive Maintenance, and Overall Equipment Effectiveness.
•Recruiting and developing a high-performance team and workforce planning across the department.
•Optimizing the cost of production by controlling the costs of in-direct materials, material wastage, & cost of handling materials.
•Designing training schedules for recruits and aligning training with an organization`s strategic goals.
•Managing the factory assets - Moving & Non Moving material and coordinate with vendors for ensuring quality product deliveries are made on time. Develop systems and processes that track and optimize productivity and standards, metrics and performance targets to ensure effective return on assets.
•During the Crisis Situation Managed very Well the Situation in terms of Cost Reduction, Overtime Reductions, Wastage Reductions and enhanced the Productivity in same level with less manpower and less working hours
•Appreciated From the Management for best handling during crisis situations also
•Implemented Automations in possible ways across the factory operations
•Executed the health & Safety concern and created best awareness among the employees
• ISO Implementations and Maintains the Labor laws
•Customers appreciations for continuous improvements on quality of products and on time Deliveries
•Actions Taken and Highly Reduced the Accumulated inventories and utilized non-Saleable inventories in to process and cleared
•Effective planning & utilization on Raw materials, Consumables & Accessories & Spare Parts
•Diplomatically Managed 500 employees from various nationalities created best industrial professional work environment
•Analyzing employees skill and necessary actions for the skill improvements on their jobs
Organization Name: Al Tawfiq Co for Plastics Manufacturing (Leading Plastics Manufacturing Industry in Middle East)
Location: JEDDAH, Kingdom of Saudi Arabia
Key Responsibility : Responsible For Entire Operations (from Raw Materials to Final Finished Product ) - Production, Maintenance, Quality control, Ware house, manpower managements, Business Development & product developments are in direct Responsibility and closely associated with other Departments i.e Sales & Marketing, Finance, Procurement and Logistics Dept, HR & personal Departments
Key Accomplishments:
•Initiating steps for continuous improvement, reducing costs and lead times, optimizing performance and delivering innovative solutions at every opportunity.
•Optimized the Product Quality in every stage of manufacturing process
•Implementing the art of monitoring production output and costs and adjusting processes and resources to minimize costs. Implement various techniques like Value Engineering and Value Analysis, Total Productive Maintenance, and Overall Equipment Effectiveness.
•Recruiting and developing a high-performance team and workforce planning across the department.
•Optimizing the cost of production by controlling the costs of in-direct materials, material wastage, & cost of handling materials.
•Designing training schedules for recruits and aligning training with an organization`s strategic goals.
•Managing the factory assets - Moving & Non Moving material and coordinate with vendors for ensuring quality product deliveries are made on time. Develop systems and processes that track and optimize productivity and standards, metrics and performance targets to ensure effective return on assets.
•During the Crisis Situation Managed very Well the Situation in terms of Cost Reduction, Overtime Reductions, Wastage Reductions and enhanced the Productivity in same level with less manpower and less working hours
•Appreciated From the Management for best handling during crisis situations also
•Implemented Automations in possible ways across the factory operations
•Executed the health & Safety concern and created best awareness among the employees
• ISO Implementations and Maintains the Labor laws
•Customers appreciations for continuous improvements on quality of products and on time Deliveries
•Actions Taken and Highly Reduced the Accumulated inventories and utilized non-Saleable inventories in to process and cleared
•Effective planning & utilization on Raw materials, Consumables & Accessories & Spare Parts
•Diplomatically Managed 500 employees from various nationalities created best industrial professional work environment
•Analyzing employees skill and necessary actions for the skill improvements on their jobs
Dangote Agro Sacks Limited - Lagos / Nigeria
Designation: Factory Manager / Acting GM | Duration: January 2011 - April 2015
Company Profile: Dangote Group is one of the Most Diversified Business Conglomerates in Africa. Having Capacity of 500 Million AD Star Bags/Annum which is the World High Capacity of Cement Bags Manufacturing. The Group into Manufacturing of Cement with Capacity of 14 Million MT/Annum throughout the African Countries and owned Cement Terminals. The Dangote into the Manufacturing of Flour, Sugar, Salt, Beverages, Food Products. Oil & Gas, and Power.
Key Accomplishments:
•Spearheaded the entire Life Cycle of the product like Cement Bag, Jumbo Bag and Small Bags from raw materials to finished product end-use. Reviewed and approved adequate plans for the control of planned outputs, budget spending, labor efficiency, material efficiency, engineering effectiveness, customer service, and order entry efficiency, along with human utilization
•Developed new process concepts for production optimization, yield improvement and formulating guidelines for the sequencing of various operations in the plant.
•Initiated the Re-Structuring of the bag construction and successfully reduced the bag weight from 90grams to 70grams and achieved optimum performance in cement filling. This was highly appreciated by senior management and also received positive feedback from customers.
•Success in reducing the rejection rate from 17% to 8% of the convertex process consistently.
•Efficiently conducted re-engineering in Extrusion, Looms, Lamination, Printing, and Convertex and Standardized all Set Parameters and Adjusted the Machinery by Trail & Error Methods, which was highly appreciated by senior management.
•Key person to design, develop and construct a star, Small & FIBC Bags.
•Diligently created MIS Report System to manage massive amounts of data on particular men and machine performance. Implemented the hourly reporting system for better monitoring and achieved the target by enhanced control over the production process.
Qatar Polymer Industrial Co is one of the Leading Packaging Industry in Qatar equipped with innovated Equipment for manufacturing of FIBC, HDPE/PP Woven sacks, LDPE Films Strapping Band Etc engaged with a workforce of 600 Employees.
Key Accomplishments:
•Resolved various technical problems in machinery which were non-functional and restarted the Tape Plants, Looms, Blown film extruders, Sewing Machines, Needle Looms & utilities Like Chiller Plants, Compressor, etc.
•Increased the production capacity to 80% from 50% by restarting the breakdown machinery and strategically arranging the spare parts.
•Implemented Regular Maintenance for Better utilization with higher efficiency. Designed the maintenance strategies and framed/enhanced processes in support of continuous improvement programs.
•Strategically undertook projects of installing recycling the equipment. Success in equipping the recycling plant and achieved production around 1000 MT of RP Material / Month.
•The main person to equip the plant for workshop facility and achieved cut down the production cost.
FIPCO - FILING AND PACKAGING MATERIALS - RIYADH - KINGDOM OF SAUDI ARABIA
Designation: Production In-Charge | Duration: June 2008 - June 2009
Company Profile: FIPCO is one of the largest Packaging corporate companies in the Middle East and En ISO 9001 certified equipped with innovative and advanced technological machinery imported from Germany. Largest producer and exporter in the Middle East with the workforce of more than 1000 employees engaged in manufacturing of FIBC, VALVE BAGS, SMALL BAGS, LENO BAGS, TWINES, CABLE FILLER, and LDPE FILMS, etc
Key Accomplishments:
•Suggested and implemented 8x8 Mesh for small bags instead of 10x10 to increase the production rate. This was passed by QC and increased the production rate by 12%. Also conducted a similar experiment with 6X6 mesh instead of 10X10 for valve bag. Increased the output of tape plant with less wastage and reduced tape loading time in looms.
•Suggested Omega style Stitching for Jumbo Bags instead of Zuki Type Stitching. This led to higher productivity with less manpower.
Top industries Ltd is one of the second largest company in Ghana (West Africa) engaged in manufacturing of HDPE/PP woven sacks & FIBC also having the production of molding of household articles and packaging goods (chairs, kitchen, and dining wares, shopping wares, agricultural PVC Fittings, etc)
Key Accomplishments:
•Production Rate was increased by 10 % as compared to previous data of 8% with a reduction in wastage by 3%.
•Received high appreciation from senior management for effective overhauling the machinery and utilities which increased the machine efficiency.
•Maintained optimum asset health for all plant equipment, systems, and structures by performing inspections, repairs, and modifications to equipment and structures.
•Successfully Erected New Tape plants and Looms.
Alagiri Spinning & Weaving Mills Pvt Ltd is one of the leading companies in south India promoted by Sri Ram Group of companies. Fully engaged in the manufacturing of HDPE/PP Sacks & FIBC. Domestic and Export sales from 1980.
Key Accomplishments:
•Increased productivity by 15 % by motivating the team for optimum performance.
•Received award from management to effectively handle the factory administration. Was selected as an Authorized signatory for all legal compliances.
AREAS OF EXPOSURE:
Production Strategies: Review and approve adequate plans for the control of planned outputs, budget spending, labor efficiency, material efficiency, engineering effectiveness, customer service, and order entry efficiency, along with human utilization.
Product Quality: Complete Quality Chain responsibility, for product line improvement actions from Vendor to Customer.
Production Operations: Plan production operations; establish priorities and sequences for manufacturing products. Ensure that the team is operating to meet the manufacturing plan to ensure on-time deliveries to internal and external customers while maintaining quality.
Resource Management: Coordinate daily operational procedures and control are daily work-in-progress for the product line.
Supply Chain Management: Integration of finished goods inventories with the sales forecast.
Business Development: Apply an in-depth understanding of customer/market needs and identifying value creation opportunities for companies to engage customers with products/services. Interact with both existing and potential clients. Tap nascent markets and develop sales strategies and plans, in conjunction with the Product Managers, to maximize market penetration and develop new market opportunities.
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