General Manager Operations
Panther Tyres Limited
Total years of experience :30 years, 2 Months
Panther Tyres Ltd. is one of the leading Tyres Industry in Pakistan, manufacturing Tyres & Tubes for Motor Cycles, Rickshaw, Light Trucks, Vans and Tractors. Also exporting toTurkey, Middle East and South East Asia.
Responsible for all plant operations such including Supply Chain, Administration, Engineering, Quality and HSE, leading a team of Department Heads and managing a work force of 2400 employees to deliver on Business Goals & Objectives and ensuring Productivity, Quality and HSE with cost effective Factory Over Heads.
Achieved highest ever production records in 2016 month on month with 29.4% increase in Production and Major reduction in Energy by 11.51% and Wastages reduced by 11.7%
Senior Management position, heading the Production Department. Responsible for efficient & reliable Operation & Maintenance of Production Lines such as Glass, PET& Tetra Lines, Utilities and Auxiliary Plants. Develop and lead a team of Line Managers to deliver Departmental Objectives and KPIs on Productivity, Efficiency, Quality, HSE, Wastages and Budget Controls.
Major Achievements:
• Revamping de-rated Injection Molding Plant to design capacities & efficiency.
• Increasing over all Line Efficiencies by 5% and Reducing Wastages by more than 25%.
• Energy Fuel cost reduction by replacing Diesel Fired Boiler with Duel Fuel HFO / Diesel Boiler.
• Introduced & implemented concept of “Operator Custodianship “ on Production Floors.
• Installation & Commissioning of new Chinese Glass Line and Krones PET Line and Relocation of Utilities Plant.
Additionally Rotational Chairman of Management Committee comprising of all departmental heads: Sales / Production / Supply Chain / Finance / Quality& Procurement. Committee is responsible for all operational matters of the Business such as developing Annual & Monthly Business Plans for MDs approval and execution & monitoring of Business Plans on day to day basis.
Senior Management Position, heading the Engineering & Technical Department for both BHP & RYK Plants,
comprising of various sections such as Utilities, Electrical & Instrumentation, Mechanical Maintenance, Tetra Pak Maintenance, Projects, Civil and Technical Store.
KEY RESPONSIBILITIES
- Provide effective leadership and professional guidance to the Sectional Managers in delivery of Departmental Objectives & KPIs, in line with Business Goals.
- As member Extended Management Committee, provide Technical support to the Business at Strategic Levels such as Growth; New Product Developments; Operational Reliabilities, Sustainability, Efficiencies and Expansions.
- Develop and execute Annual Plans for Technical Over Heads, Capital and Major Repair & Maintenance Expenditures, and Technical Store Inventories.
- Utilities Section is the Business Critical area of responsibility including Primary 3MW Gas Generator and Stand-by Diesel Gen Sets, Steam Boilers, Chilling and HVAC Plants, Compressors etc. Ensuring periodic maintenances as per OEM schedules.
MAJOR CONTRIBUTIONS
Developing Team towards Manufacturing Excellence through GEPs ( Good Engineering Practices ), Engineering and HSE Standards, ISO Standards.
Major Projects Executed
A-New 3MW Gas Power House Total project responsibility as Initiator, Conceptualization
Vendor selections, Techno-Commercial Assessments,
Installation & Commissioning of JGS-620 GE Genbacher
Gas Generator.11kV / 415 distribution designed and installed in-house
B- New DCS Control System for Powder Plant
C-Filling Hall Air Conditioning
D- New Cheese Plant
E-New Juice Plant
F-Water Treatment Plant
G-Modern New Office Block
H-New Ware House
I- In-house up-gradation on all Pasteurizer Plants with Automated
Recipe Control
J-General Plant Improvements.
Reduction in Energy & Maintenance Costs.
A- Saving of Rs 4.0mil per month in overall Energy Cost by
installation of 3MW Self-Generation and 70% reduction of Wapda
Load
B- Regular review of Inventories Order Levels based on historical consumption trends.
C- Deletion Program for costly imported parts through Local Developments
Enhancement of Plant Reliability through Engineering Audits.
A- Revamp & up-gradation of largest Boiler #4
B- Phased Replacement / Refurbishment of aged out and obsolete
equipment.
-New Cooling Towers for Powder Plant & Water Chiller #4
- New DCS Control System for Powder Plant.
C- Capacity enhancements to cover shortfalls in system
- New 2 Cusec Plant WaterTube Well .
- Stand- bys units for critical duty equipment
- 24000 LPH UHT Plant#5
- 20000 LPH Cream Pasteurizer Plant
Organize, guide and lead two sections: Electrical and Instrumentation Section / Power Services Section
Responsible for both the sections to attain operational objectives and targets, leading a team of 8 managers/engineers and
72 staff with additional responsibility as Operations Manager, Power Services Plant.
Core responsibilities include:
A: Develop professional competencies and skills in teams .nculcate professional work methods and sound engineering practices and systems in the sections.
B: Operation, Maintenance & Development of Plant, Equipment and Systems
• 8.45 MW Co-generation Power House consisting of 5.25 MW Gas Turbine and 3.20 MW Steam Turbo-Generators.
• Power Distribution Network, HT/ LT switch gears, Stand-by Gen.-Sets and 3.3kV motors.
• 110 Ton/hr Boilers House for HP, IP & LP Steam generation
• Compressor stations for CO2 gases and Instrument Air.
• AC/DC Variable Speed Drives
• DCS and PLC based process controls on plant : ABB Symphony DCS, Foxboro IA Series DCS, Siemens and Allen Bradley PLCs.
• HVAC Systems.
• Plant Fire Alarm System and Emergency Response Public Address System.
• SAP / MAXIMO based plant routine, preventive & shut down maintenance systems.
C: Expansion and De-bottlenecking Projects.
Key involvement and technical support in major Business
Projects and medium size development and up-gradation
projects.
Played major role in US $ 11.0m projects of DCS Automation
and 5.25MW Alstom Gas Turbine, in all stages from
development of FEDM and Bid Document to Vendor
pre-qualifications, Technical and Commercial assessments and
award of contracts.
Conceived a significant engineering solution of a load shedding system for the Power House and developed a philosophy that has worked successfully and saved millions of Rupees for the Business by avoiding total power black outs at the plant.
In-house capital projects worth Rs.30m for development jobs were completed . This included design and construction of new 2000kVA 11kV/ 415 V sub-station, 1380 kVA Wapda /Works 11kVA Change Over Switch Room, new LT distribution network for the plant from the gas turbine and revamp of old and obsolete field instrumentation and control rooms.
D: Commissioning and start up of Major Expansion Projects
Ensuring installations as per standards, carrying out FATs &
SATs and smooth commissioning and start-up forms a lead
responsibility on such projects:
• 180 TPD Continuous Polymerization Plant at Polyester Works in
1997 by Chemtex, USA DCS Plant Automation at Soda Ash
Works in 2001 by ABB Singapore.
• 63 KTPA De-bottlenecking Project at Soda Ash Works in 2001
• 5.25 MW Co-generation with Gas Turbine at Soda Ash Works in
2002 by Alstom Power UK.
E: Control Spares Inventories, Capital and Revenue Expenditures
Optimal stock levels and cost effective replacements of parts.
F: Implement Engineering and Safety, Health & Environment
Policies, Standards & Procedures
G: Implement SAP Applications in areas of responsibility
H: Develop procedures and maintain systems for ISO 9001
Certification and Surveillance Audits
Responsible for managing Electrical and Instrument sections of Engineering Dept. at the factory. Additionally responsible for E & I installations related to continuous process Sulphonation Plant
Lever Chemicals (Pvt). Ltd. Rahimyar Khan.
A: PROJECTS
Independently handled projects in the range of minor to medium size projects of 6-month duration.
• Hard Soap Process Automation
A 6-month project for Installation & Comm. of Honeywell 9200e
Process Control and SCADA System. Independently handled the
retrofit project on a running process, starting from project
scheduling using PERT/GANTT charts, controlling logistics and
installations to commissioning.
• Transnova Case Packer Restoration.
A project for complete rehabilitation and restoration of PLC
controlled Transnova Case Packer. The machine lying inoperable
and grounded with no supportive documentation and a
typical "BLACK BOX" case machine, was restored with
- New Electrical Documentation
- New Siemens Simatic S-5 PLC
- In-house development of configuration and testing of new PLC
program
- Up-graded Control Panel.
B: Major Development Jobs
• Auto- Ignition System for Boiler House
Totally designed and developed in-house and 30 years old unsafe
and difficult ignition procedure up-graded.
• New PC based Factory Weigh Bridge System.
An old, problematic unit replaced by a more reliable, flexible and
cost-effective system, designed and specified in-house
Responsibilities included:
- Routine maintenance of Instrumentation and Control Systems.
- System up-gradations, modifications and new design and
developments.
- Installations and commissioning of new projects.
- Spares requisitions and maintaining spares inventories.
Maintaining Process Control System such as Analog and Digital PID loop controls, PLCs, AC/DC Variable speed drives and mill-wide Accuray computer control systems.
Installation and commissioning of new projects such as ABB Master 200 DCS System for Paper Control, PLC Controlled Flexo Printing & Lamination Machines, 11kV Sub- Station and distribution using Gantt Charts for project handling.
Maintenance of controls on 6 MVA steam turbine power house.
.)