Vice President Manufacturing Quality
Dawlance Group of Companies
Total years of experience :25 years, 8 Months
• DPL1, DPL 2 plants in Karachi and URIL Plant in Hyderabad are under my responsibilities.
• Responsible for Product Quality, Internal and External Quality Cost, SCR, Labs, Calibration, Process Engineering and CI.
• Departmental strength is about 185 from all three plants.
Key Responsibilities;
• Production, Quality and Process Engineering departments were under my direct responsibilities.
• Established Plant Policies & Procedures, Reviewing and approving plans for achieving planned output, Budget preparation & control spending, Material efficiency, Engineering effectiveness, and Foster a well trained and motivated production team;
• Establishing strong working relations with other functional managers.
• Weekly and monthly Presentations to GM on Plant performance and results.
Achievements:
• Increased Machine efficiencies from 82% to 97% by deploying OEE model in both Plants and reduce substantial percentage of waste (i.e. from 3.5% to 0.65%) in 14 months.
• Recycled 100% PVC sheathing waste in bedding process with ratio of 50 / 50 percent.
• Worked on manpower plan and reduce 7% of production staff by automation and relocation on machines this was successful by using Time & Motion Studies and through the development plans of the workforce.
• Successful production of single core HV cables (66kv, 110kv & 132 kv) and get certification form KEMA (Netherlands).
• At the time to leaving the company, special thanks & appreciation letter from Managing Director of the company may show upon request
Manager Quality at PHILIPS Lighting Pakistan
• Scope of responsibility Covers Product Quality of Lamps & Luminaire (that includes, Raw Material Inspection, Process Quality, End Quality, Laboratory, Customer Complaint & Product Replacement), and Quality Management System for Industrial (that includes ISO 9001:2000, Continuous Improvement Program, PBE similar or equivalent of Dubai Quality Award.
• Managed quality aspect of four key vendors of Luminaire. Anticipated and detected bottlenecks in terms of high DPPM which reduced from 6000 to 1400 by implementation of SPCs on critical process parameter and strengthen the material inspection procedures at vendor premises.
• Lead BEST excellence tools for industrial process management and continuous improvement projects. From these projects approximate annual saving achieved Pak Rs. 11.5 million in 2006 / 2007.
• Successfully completion of local TLD manufacturing and get approval of samples from regional product development centre Bangkok, Thailand.
• Organize and involve with Plant Manager for policy deployment process and monitor through Balance Score Card. Responsible for maintaining ISO-9001:2000 certification. Organized ISO 9001, PST, CCA internal audits and prepare the organization for the external audits
• Played vital role in several projects at QIT platform such as direct packing by eliminating 8-hrs Quarantine time in TL factory, DPPM reduction by strengthen monitoring of critical process parameters and develop / deploy OCAPs, Reduce short life of Luster Lamp by conversion of gas filled lamp into vacuum lamps.
• In depth knowledge of Cost of Quality (COQ), Reduced Failure cost by optimizing conditions of Prevention and Appraisal cost. In this context SOPs of incoming material inspection and process control sheets were reviewed and shared with AP regional best factories.
• Developed monitoring and measurement procedures for utilities consumption (for Factory and subsequently Per Product piece) based on Eco-Vision guidelines. Optimize processes on the basis of results measured and reduced energy waste by induction of short and long term projects.
• Ensured the manufacturing process through Statistical Process Control (SPC) on significatant product / process parameters.
• Carried out QFD, FMEAs periodically or as deemed necessary.
• Maintained the Cpk’s of significant product / process characteristics (> 1.33) which derived from QFD exercise.
• Custodian of four elements (Control plan, Process Capability, Process Control & Reaction to problem) of PST Manufacturing Management guidelines and procedures.
• Supplier development by implementing control plan and SPC activity at supplier ends.
• Facilitate, educate and coach organization’s people in use of Excellence process tool e.g. SPC, DOE, MEDIC, FMEA, PDCA cycle, ISO 2859 Sampling based inspection procedures and PSTs.
• Coordinate assignments with supervisors for effectively utilization of workforce, equipment and material to meet the production schedule and targets.
• Maintained and managed day to day operations, Yield, cost and quality objectives.
• Monitoring special projects related to increasing efficiencies and lower rejects.
• Control the level of rejections by strict adherence to prescribed manufacturing practices and machine operation standards.
• Preparation and circulation of Daily production Report (DPR) to Plant Manager and relevant department.
• Identifies and recommend opportunities for improvement, implement improvement action plans and follow-up.
• Responsible for execution of preventive maintenance schedule and procurement of spare parts requirement with coordination of maintenance and procurement department.
• Conduct ISO 9002 internal audits and Philips Process Conformance Cycle Audits.
• Production Planning for Electric Iron, Hair dryer, Citrus Press and Fan-Heater.
• Time and Motion study according to production plan.
• Induction of new Product Launching (Electric Iron, HI-108 type).
• Participated in development of Quality Management System w.r.t. ISO 9002:1994 standards for Domestic Appliances Factory and achieved Certification from SGS Malaysia, in December ‘1998.
--Cummulative GPA is 3.27. --Member of Pakistan Engineering Council, Islamabad, PAKISTAN, since 1998.