process engineer
joriki inc
مجموع سنوات الخبرة :6 years, 6 أشهر
• Experienced working in a highly automated environment like Tetra Pak filling machines, batch tanks, blenders, aseptic tanks, pasteurizers, Accumulators, straw applicators, Film wrappers, cardboard packers, etc.
• Identify problems, determine root cause, rectify, or recommend solution using continuous improvement, lean six sigma, 5WHYs, DMAIC, etc. to avoid issues reoccurring.
• Leading a large-scale automation project (houdijk) and kibbler project as a VSU leader to minimize error & improve productivity which increased line global efficiency (GE) by 10%.
• Manage long-term & short-term project related to KPIs scorecard gaps for improvement.
• Reduced yield waste from 9% to 6% through implementation & execution maintenance program and equipment modifications.
• Conduct equipment trials then collect & analyze data, generate reports summarizing the results of trials then calculate overall cost savings.
• Standardize CIP time, highlight downtime issues, which increased OEE by 4% per CIP duration.
• Implemented Poka-Yoke mechanism on film wrapper, labelling correct way on machine, which improved process, reduced error occurrence, & increased OEE of line by 2.5% per shift.
• Labelled tools & colored them by assigning designated tool stations thus Implementing 5S technique to reduce downtime and improve workflow.
• Maintained & improved production line KPIs like quality, safety, morale, waste, global efficiency, overpack and present it to operation manager in DMS.
• Worked as a Production supervisor under the general supervision of (operations manager -Tetra Pak) to lead a team of 30+ on multiple production lines.
• Act as a team lead for Batching, Manufacturing, and packaging for liquid food (low & high acid beverages) for brands like Coca-Cola, Nestle, Unilever, Walmart, etc.
• Conduct pre-shift huddles and provide feedback to the team members on production, CIP (full/partial), changeover, line shutdown, etc.
• Worked with QC Techs, filler operators, Batchers, packers, & fork lifters to ensure start-up check, on-time start, assign labor, material set up, & line inspected for smooth production.
• Check daily production report, raw material usage record, production delay, and problems encountered are filled out clearly and completely by the team.
• Make sure new team members are trained properly and have the necessary skills to perform required duties in a safe and effective manner.
• Manage labor cost with focus on absenteeism, overtime & temporary labor with Labor Scheduler. Managed Kronos timekeeping system ensuring all hours worked are correct.
• Coordinate with mechanics to troubleshoot machine & preventive maintenance (PM) to avoid unplanned breakdown or downtime and meet OEE targets.
• Introduced Quick Kaizen at workplace; production team to come up with idea and then develop SOPs & OPLs for improvement in safety, lean, autonomous maintenance, & TPM.
• Provide safety leadership, ensure QRP/STOP observation GEMBA walks are happening, accident & incident report are completed. Identify root cause & implement solution.
• Calibration and troubleshooting of equipment such as colorimeter, Ph Meter, Foss, Stackometer, Oxylos airtightness, Salt meter, fluke thermometer, scales, etc.
• Performed Pathogen Environmental Monitoring (PEM) programme for different zones in a timely manner. Also did swab (Investigative, allergen, salmonella, listeria, clean equipment, pre-clean, and post clean).
• Performed peanut-free testing on a finished product and released the product on SAP.
• Performed Oreo film (snack & seal test) to make sure the defect rate is less than 5%.
• Monitoring and recording all deviations that occur in flour and sugar tailing like metal pieces, insects, wooden pieces, bees, etc., and reporting to the Quality team lead.
• Requesting and reviewing CAPA/RCA from the suppliers of raw material and packaging material that are not in compliance with company standards.
• Released packaging and raw material using SAP by entering values from COA.
• Generate quality notifications through Internal/ external rejection of packaging and raw material using SAP.
• Passed QCMS audit and scored 94% in FSSC22000 audit.
• Release, Hold, and Rejection of material at receiving area.
• Performed periodic line checks and record data using Brix, citric acid titration, Vitamin C titration, solid and fat analyzer, sodium analyzer, salt analyzer, density meter, viscosity meter, etc. to ensure finished products are within specifications.
• ATP Swab - fillers, batch tank, mixer, blender, aseptic tank; etc.
• Maintain Health & Safety-hygiene work environment by enforcing company standards, GMP policies, safety procedures. Also participate in monthly Health & Safety meetings.
• Performed peroxide check, chemical check, and final rinse check.
• Adjust batch release for the batchers according to the batch sheet specifications.
• Review and modify E-QCMS forms like lab equipment specifications and serial number, verification and calibration procedure of lab equipment, batch sheet specification, etc.
• Periodically documenting pasteurizer and aseptic tank reading in the monitoring record.
• Performed chlorine tests on the main water source on a weekly basis.
• Arranged external calibration of lab equipment’s before the expiry date and maintained calibration database.
• Conduct hourly inspections to ensure finished product shape, size, weight, lot number and date codes are recorded properly in daily production sheets during each shift.
• Dissolved tetra Pak samples every 6hr using muriatic acid then put the samples in water tub and add baking soda to find any leakage at the transversal sealing.
• Participate in startup, shutdown, and changeover to ensure it takes place efficiently and effectively.
• Maintained a safe, organized, & sanitized environment at workstation during shift end.
• Monitored key performance indicators (KPIs) to ensure production goals are met.
• Monitor control panels of mixers, freezers, fillers, batch tanks, blenders, aseptic tanks, pasteurizers, etc. to determine whether control setting meets company specification.
• Sending finished product samples every 1hr to quality lab for testing purpose.
• Collect retention, customer & microbiological samples and store them in assigned area.
• Performed package integrity check on tetra Pak sample to find any leakage on the top & bottom surface, sealing area, edges, longitudinal sealing, straw hole area, etc.
• Participated in team meetings & training sessions to improve the production process.
• Responsible for practicing & adhering to Food Safety, SOPs, GMPs, HACCP and Health & Safety policies at all times.
Six sigma Process improvement Technique, Total Quality Management, Lean Production System, Materials & Testing Lab, Communication for Quality Assurance, Workplaces and Health & Safety, Implementation of Quality Management Systems, Continuous Improvement Techniques, Statistical concept for Process Control, Quality System Auditing, Problem Solving & Decision-Making Techniques, etc.