PLANT MANAGER (Head of Manufacturing)
Emirates Industry for Camel Milk and Products
Total years of experience :29 years, 10 Months
Biggest and most unique Integrated Camel Milk Processing Unit, approved from European Union for world-class R&D and manufacturing facility
Performance driven Front-Runner: Providing strategic oversight for managing existing Manufacturing Facility in 3 Units, two in Dairy and one in Beauty Care Verticals for key deliverables of Health, Safety, Quality, Productivity, Sustainability and New Product Development with a team size of 80 people from different nationalities. Leading direct reports comprising of Production Officer, Product Development Manager, Maintenance Engineer, Finished Goods Stores In-charge, while reporting to CEO, driving revenue and business growth across global markets. Driving Improvement in Productivity, OEE to achieve World Class Standards, mentoring Value Stream Optimization Projects to achieve defined savings target
Plant Operation, Projects, Lean Manufacturing:
• Directing Plant Operations, conceptualizing and implementing Annual Budget, SOPs Strategies and Policies in sync with organization vision and mission, ensuring maximum efficiency, productivity with key focus on P&L
• Driving and implementing Lean Manufacturing Practices, Quality Assurance & Control with focus on Reduction in CPM (Complaints per Million) across all products, improving First Time Release (Target 99.9% from current 99.5%)
• Administering Preventive/ Predictive /Breakdown Maintenance Schedules of plant & machinery to reduce downtime, optimum equipment efficiency, substantial reduction in O&M expenditures
• Ensuring 100% Compliance to Production Plan with OTIF (On Time in Full) Delivery for increased Customer Satisfaction
• Leading all upcoming / existing projects as Project Lead. Coordinating project functions, assessment of current and future project requirements and placing them with justification, to finish on time with all agreed deliverables
• Responsible for selection, negotiation, sourcing of process and utility equipment and their successful commissioning
Sustainability, Product Development, HSE:
• Identifying and integrating Sustainability Opportunities for maximizing sustainability, reducing carbon foot-print, adherence to environment regulations, positively impacting company's image
• Facilitating measures for continuous improvement, by streamlining existing processes as well as designing new processes to minimize rejection, optimize resource utilization, achieve operational efficiencies, control costs and cycle-time
• Administering Health & Safety, driving drive TRIFR (Total Reportable Incident Frequency Rate) to world-class standards, leading safety efforts within the plant, monitoring safety performance and ensuring coaches provide appropriate training and direction for a safe working environment, zero fatalities and injury
• Identifying performance bottlenecks, conducting review of customer complaints, RCA and accordingly driving Corrective Action & Preventive Action (CAPA) to prevent reoccurrence and high-customer satisfaction
• Overseeing New Product Development as a tool to improve sustainability. Managing operating activities and ensuring all products are manufactured/packaged on schedule, within quality standards and cost objectives
• Analyzing Market Survey Reports, timely introduction of new products in existing verticals, supporting required changes in existing product portfolio to match market requirement
• Facilitating and reviewing MIS Reports / Dashboards for enabling critical decision-making and future strategy planning
• Headed a team of direct reports - Production / Engineering and Outbound Stores Managers and in turn reported to Operations Manager
• Led and executed a Greenfield Project as Technical Head entailing successful erection and commissioning of a Spray Drying Plant, meant for Drying Gum Arabic Powder and Instant Milk Powder with a capacity of 30 MT/Day
• Effectively analyzed Contracts with Vendors, identified, and pointed out at least 10 Major Changes required in the project
• Efficiently headed operation of 2.5 million Liters of Milk/Day producing 20+ different products in a fully Automated Manufacturing Facility with a multi-cultural team of 110 people including Continuous Improvement Managers and Team Managers
• Drove Quality/ Productivity Improvements, achieved reduction in reworking due to process issues by 25%. Identified losses through Lean technique, addressed Downtime issues through proper MTBR & MTBF analysis and implemented corrective actions
• Led Sustainability Programs to meet or improve LIP (Loss in Process) Budget, achieved 25% reduction in Drain Losses, NPL (Non-Process Related Losses) and Dumps against Last Year Actual. Reduced waste production by 5% through improved resource utilization and recycling practices
• Made more efficient production workflows by reengineering processes, leading to a 30% reduction in bottlenecks, reduction in Expats & Local Employees turnover and a 15% increase in throughput, which helped increase plant productivity and ensured timely order fulfillment (OTIF)
• Successfully implemented Key Projects like:
- Loss & Waste Project on Dessert Products with an identified Zero-base Opportunity (Capital Deferment) of 1.2M SAR in 2010-11
- Project on Reduction of Startup Wastage in Canned Products and saved an amount of 600K, in 2012
- CIP Optimization Project on Pasteurizers with opportunity of saving 700K SAR per annum and saved 470K in 11 months
• Sep 2001 - Oct 2009: Mother Dairy Foods Processing Ltd, Delhi, India (Subsidiary of NDDB) || Asst. Manager - Production:
o Responsible for overall Yoghurt Production and 10 Filling Lines, with a team of 90 members.
o Supervised 3rd party operation as Facility Manager for Mother Dairy.
o Worked in SAP Implementation Project of Mother Dairy as Core Team Member.
o Successfully commissioned a Capacity Expansion Project from 20K/day to 60K/day in 2003.
o Significantly brought down cost per CPU in Dahi (Yoghurt) through process optimization
o Worked on Key Projects like Productivity Improvement Project by increasing Air Quantity without affecting Reconstitute Ability of Dairy Whitener.
o Erection/Commissioning Greenfield Project; 30 Ton Alfa-Laval Five Effect Falling Film Evaporator and L&T- Niro Spray Drying 2-stage Spray Drier Project with FBD (Fluidized Bed Dryer) for Instantization within set time and quality standards.
o Ensured successful running of the Spray Drying Section as In-charge Spray Drying.
o Oversaw end-to-end activities from milk intake to processing followed by filling of products in an 8-hr. shift.
o Responsible for achievement of productivity target with quality products in a safe environment
Project Management Professional. Completed two projects as part of study