Manufacturing Manager
Unilever Pakistan Limited – Beauty & Personal Products Plan
Total des années d'expérience :14 years, 1 Mois
Working as Manufacturing Manager (Dec 2023 - Till date)
• Develop and execute strategic plans to optimize operational efficiency and drive business growth.
• Lead and mentor a team of operations managers and supervisors to ensure alignment with organizational goals.
• Oversee all aspects of manufacturing operations, including production planning, inventory management, and quality control.
• Collaborate with cross-functional teams to streamline processes and enhance productivity.
• Champion a culture of continuous improvement, innovation, and excellence across the organization.
• Monitor key performance indicators and implement corrective actions as needed to meet targets.
• Ensure compliance with regulatory requirements and industry standards.
• Strategic negotiations with CBA team & leading a site of over 300 FTEs.
Achievements unlocked: 1. Blind winning Product against eye-ball competition. Massive product superiority with cost savings. 2. Major unlocks of margins through consumer testing of VIP formulations maintaining product superiority with 5S Savings of ~ 1.5Mn Eur. 3. Ambitiously creating savings funnel / roadmap ahead of the 5S target. 4. Localization of game changer innovations - Surf Excel Liquid & Domex Acid in Pakistan market for the first time. 5. Clean future - Deployment of KF formulation of Comfort Fabric conditioner. 6. Localization of Vim Dish wash liquid. 7. Landed innovative & CF formulation of Surf Excel Fab. clean powder with completely new Packaging Development.
Responsibilities:
• Closely connecting with consumers, learning about their pain points and developing technical briefs with BU leads.
• Providing overviews and insights of formulations, raw materials, alternate suppliers and manufacturing sites, including specifications optimization.
• Leading and contributing to the resilience projects and programs related to material or product supply issues.
• Leading all innovations, 5S, Product design & deployment networks partnering with RDC & GDC.
• Driving holistic superiority through active competitive benchmarking, consumer connects & technical insights
• Performing consumer connects and turning key insights into the technical product briefs.
• Performs / seek cross functional alignment across BG stakeholders such as Marketing, Supply Chain, Quality etc..
• Conducting Technical Appraisals & active benchmarking against major competitor from consumer lens.
• Providing R&D leadership to create and realize 5S / E2E savings program.
• Capability development for myself & my team through FFP, follows learn, unlearn & relearn principles.
• Working closely with Senior leaders in the BU and interface with the BU procurement and supply chain leads, collaborative manufacturing partners as well as factory teams.
• Supporting factory team in major unlock of capacity by optimization of formulation design which helps reducing batch cycle time & changeovers without any compromise on product quality.
Worked as Assistant Manager Plant Operations, Foods Factory (Jan 2020 - Dec 2020)
• Weekly production planning with Supply Planner.
• Setting manpower requirements for the week and optimizing manpower / overtime cost.
• Working with supervisors and shift managers to schedule production priorities.
• Leading continuous improvement initiatives and developing alternatives to optimize FOE.
• Responsible for employee development, discipline, performance appraisals, and administration of policies.
• Developing standards of performance measurements on plant level, department level, circle level, team level & individual level.
• Supporting R&D trials and extending support to deliver innovation projects.
Worked as Assistant Manager Innovations & Technology (Jan 2018 - Dec 2019)
• Worked as a receiving end project manager for project Raftaar 24Mn Euro investment in Home Care.
• A project focused on Hygienic Products. Designing of a new hygienic manufacturing facility with EHEDG standards.
• Achieved milestone of producing Comfort & Surf Excel liquids with a vertical start-up on newly commissioned hygienic liquids plant.
• Making business cases for budget approvals regarding capacity enhancement.
• Leading Optimization of existing processing / production capacities with minimum or no Cap Ex solutions.
• Represented Unilever Pakistan in design workshops at SNC Lavalin Dubai office.
• Reviews of P&IDs and layouts with Unilever Global Process Engineering Experts which resulted in design simplification and ease in maintenance & plant operations.
• Strategic planning with BU teams for capacity (covering demand-based volume growth for the next 5 years).
• Supporting procurement in performing TBAs for plant machinery & equipment.
• Planning proactively for capability development, optimizing quality, HSE & ergonomics.
• Technology selection for hygienic equipment, defining standards of CIP, COP and OPC.
• De-bottlenecking of production capacities by means of Run Strategy Optimization, Various Automation, Autonomous Maintenance - WCM and Resource Capability Development.
• Working in close coordination with R&D, Logistics, Quality, Manufacturing, Sales, and Marketing & Packaging Development teams for product innovation & savings projects.
• Leading core design technology evaluation in all the capacity upgradation projects.
• Defining safe execution plans during execution of brownfield projects mainly focused on safety of (workers, products & consumers).
• Providing support to manufacturing process plants for any technological troubleshooting.
• Achieved milestone of ever highest production in 2017.
• Performed quality systems revamping in 02 factories of Unilever Home Care Category.
• Successful and on-time delivery of major brown-field projects Iconic and De-bottlenecking.
• Implementation of Run strategy and optimization of process changeovers.
• 60% reduction in Repair & Maintenance cost by enhancing in-house repair capabilities & alternate sourcing.
• Challenged Biomass Hot Air Flow design & performed improvement in this area by installation of hot air FD fan of 40, 000 CFM.
• UD Plant de-bottlenecking project delivered in brown field environment with 200, 000+ Safe Man hours.
• In-depth time motion study of FCL with visual PFDs helped in manpower optimization.
• Responsible for managing engineering spares inventory and its optimization.
• R&M absolute cost reduction by 15Mn PKR by in-house repairing of weighing actuators.
• Local development of Yamato Links PKR 350 local vs PKR 89, 000 imported per pc.
• Reduced spares inventory from 142Mn PKR to 110Mn PKR within a period of 2 years.
Major responsibilities include:
• Ensure implementation of GMP, GLP & Consumer Safety Standards of Unilever
• Conducted Cleaning & disinfection validation study for hygienic manufacturing plants.
• Performing Quality & Consumer Safety audits for gap analysis on Unilever global guidelines
• Implementing robust HACCP system that guarantees consumer safety of the product.
• Coordination with suppliers and 3P Sites to implement plans to ensure and improve quality from raw and packaging materials and facilitate certifications including (ISO 9001, ISO 14001 & ISO 22716).
Worked as Executive - Production & Engineering (Feb 2010 to Feb 2013)
• Responsible for Process operations of Methylene Chloride / Solvent Recovery Plant
• Responsible for production process of sterile area, process operations & PM of solvent recovery plant.
• Safety measures, risk assessment, training & development as per GMP & ISO 9001.
• Taking actions to reduce dust emissions.
