Factory Manager
Shanns Cosmetics and Chemicals PVT LTD
Total years of experience :15 years, 1 Months
By reporting to CEO, Successfully Managing 25 departments, 300 employees and 5 project contractors in construction, IT, supply chain, operations, procurement, production, quality, HSE, optimization, technical support, and administration to complete large-scale projects within budget, on schedule, and with stakeholder satisfaction.
Synopsis of Accomplishments & Functions:
• Leading and directing multiple projects that have reduced inventory holding costs, streamlined operations, optimized efficiency, and reduced product costs. These projects include the construction of two new warehouses (15000 SQF, budget 20 M PKR; 25000 SQF, 40 M PKR), a storage racking system (20 M PKR), CMMS software implementation (10 K USD), industrial solar initiation (700 M PKR), chemical recycling water plant (10 M PKR), and housing colony construction (0.5 M PKR).
• Proposing and initiating an Industrial Solar System with a capacity of 500 KVA, which has reduced the company's carbon footprint and saved in electricity bills annually. I also managed the procurement and installation of a 500 KVA generator set, resulting in savings annually in energy costs.
• Initiating a CMMS software system across the factory, which has reduced unplanned downtime and saved estimated annual costs in electricity bills, as well as reducing MRO inventory costs. Additionally, achieved a reduction in equipment downtime and maintenance costs by implementing a preventive maintenance program.
• Redesigning lean layouts, time and motion studies, and automation by adding new chemical and cosmetics manufacturing machines, which increased production capacity and reduced manufacturing costs.
As a CEO's direct report, managed factory operations for an ISO-9001 certified public limited capacitor manufacturer with a daily production capacity of 70K units and a global export presence. Oversaw end-to-end functions, including project management, supply chain, procurement, production planning and control, quality management, maintenance, inventory management, fabrication, export logistics, technical support, and administration. Led a team of 300 employees and 3 contractors, ensuring projects were on time and within budget while maintaining the highest level of efficiency and meeting international standards.
Synopsis of Accomplishments & Functions:
• Reviewed and improved the Quality Management System (QMS) in collaboration with top management, resulting in a reduction in customer complaints and an increase in satisfaction. Maintained a 100% compliance rate with international standards.
• Collaborated with suppliers, customers, procurement, production, quality, and the Research and Development team to develop new products, resulting in increased revenue for the company.
• Optimized procurement, incoming quality inspection, process quality testing and inspection processes, production planning and control processes, reducing lead times and waste, while improving efficiency and factory conditions. This led to an increase in production output.
• Successfully led multiple construction projects, including the construction of a new warehouse with a capacity to store 100 million capacitors, reconstruction of factory boundary walls, and acquisition of two new generators with capacities of 500 KVA and 300 KVA.
As the General Manager of Factory and Customer Service at Samsung R&R Industries formerly Rockmars Industries PVT LTD, a leading manufacturer of Samsung products with over 100 employees in Karachi, Pakistan, led and established a technical team for Samsung business functions, factories, and after-sale customer service infrastructure and operations. Oversaw procurement and sourcing of equipment and plant machinery, managing a 500 million USD budget, Planning, Production, Quality, Inventory, and maintenance ensuring compliance with Samsung KPIs and global regulations. Managed all aspects of the organization's operations, including factory accounts, Admin and human resources, and close collaboration with sales and marketing. Set strategic goals and ensured the organization achieved its objectives.
• Increased annual revenue by developing and executing a program feasibility and infrastructure strategy. Led and directed the company portfolio for multiple projects, achieving production capacities of up to 300 units per day for each, including customer service network infrastructure and team buildings countrywide, Setup of Samsung Air conditioner SKD Contract manufacturing, Samsung SKD LED factory, Samsung Washing machine SKD Setup, and Samsung CKD LCM Manufacturing plant.
• Successfully planned, executed, evaluated, and finalized factory utilities and infrastructure work, including the acquisition, installation, commissioning, and maintenance of a 500 KVA Diesel Gen Set, Air Compressors system, and electrical system, and monitoring of execution. Led a cleanroom project to meet the environmental conditions for LCM.
• Improved production efficiency by implementing quality improvement initiatives, comprehensive employee training programs, and supply chain optimization, resulting in cost savings. Achieved a defect rate of less than 0.1% by implementing quality assurance processes such as IQC, PQC, OQC, VOC, QTR, 7R, and 5S.
• Implemented FIFO inventory management for raw materials, in-process, and finished goods. Developed a performance management system for employees, increasing productivity and engagement. Ensured manufacturing, quality, and HSE compliance with security policies, resulting in zero incidents or accidents.
• Expanded and optimized the customer service network by formulating a customer service strategy, achieving improved KPI results and capturing extraordinary market share and revenue. Improved after-sale service and support processes, achieving a 99% customer satisfaction rate. Utilized Samsung GSPN and GCSP portals effectively, reducing issue resolution times.
As Senior Factory Manager at Samsung-SmartZone Electronics Pvt Ltd, an official Samsung products partner with 100+ employees in Lahore, Pakistan, oversaw equipment procurement, installation, and optimized daily operations, leading a team of 100+. Managed construction project planning, execution, and monitoring to ensure successful completion.
• Managed accurate scope, cost, and schedule estimates, BOQ preparation, and material procurement for the Samsung factory project by consulting with clients, vendors, and suppliers. Monitored project sites for safety compliance and project timelines, and managed project timelines and budgets for successful completion.
• Negotiated with local and international suppliers to procure machines and equipment at a reduced cost of the capital budget, amounting to 100 million USD, resulting in significant savings for the company.
• Managed supply chain operations and service engineers training to maintain Samsung service KPIs at a 100% customer satisfaction level. Provided after-sale service management for customer satisfaction and product quality, finalizing Samsung production and customer service Level Agreements, contracts, addendums, and Memorandums of Understanding.
Orient Electronics PVT LTD is a HA & CE manufacturer and distributor of brands like Samsung, Mitsubishi heavy industries, Mitsubishi Electric, Orient, Moulinex & Midea. Promoted to Sr. Deputy Manager from Assistant Manager, improved tech capacity, productivity, efficiency, performance, and profitability via lean, kaizen, six sigma projects. Managed supply chain, Planning, procurement, Engineering, Production, Quality, Inventory Management, Customer Service and logistics, and compliance through SAP ERP 6.0 and web portals.
• Successfully Managed after-sale service operations and acted as primary liaison between Samsung SEPAK Pakistan, RHQ UAE, and HQ Korea. Reduced response time and improved customer satisfaction by implementing a new centralized customer service system with 7 CSPs, 15 Service Centers, and 120 third-party contracted workshops. Streamlined supply chain, technical operations, centralized service tracking, spare parts inventory, procurement, imports, storage, and distribution, resulting in a $5M USD service claim from Samsung. Finalized Samsung production and customer service SLA, contracts, addendums, and MOUs, ensuring efficient and productive collaboration between both companies for infrastructure expansion projects and operational optimization.
• Increased productivity, capacity, and reduced quality defects by conducting a comprehensive time/motion study and process reengineering project. Redesigned floor plans, which improved overall productivity and manpower reduction. Improved product quality and production output by implementing a new quality control system, testing procedures, and conducting regular audits/inspections. Reduced product defects and increased production output via process improvements.
• Led projects to implement authorized service tracking modules through the web. Designed a KPI system and online Service tracking in SAP CS module and Customer service XML interfacing with Samsung SAP in 2013, resulting in improved service tracking and customer satisfaction.
• Collaborated with Korean, Chinese, Japanese, and Thai engineers on major projects to prepare facility and install FPTV, Microwave Ovens, and split/floor-standing air conditioners production lines (12K to 48K BTU) for brands like Samsung, Orient, and Mitsubishi to expand its product line and improve its market position in 2010.
At PEL, an ISO-certified Electrical & Electronic manufacturer with over 6000 employees, led a team in installation, commissioning, testing, repair, preventive maintenance, and troubleshooting of control systems, including injection molding, thermoforming, CNC/MCs, assembly lines, extrusion lines, AC/DC Drive modules, inverters, PLCs, and pneumatic/hydraulic systems. Forecasted and ordered MRO inventory to achieve the requirements of CKD manufacturing and strategic objectives.
• Collaborated with Korean engineers for LG appliances CKS/SKD proposals and layout planning. Supervised PEL refrigeration assembly line installation with relay logic for automated refrigerator assembly, doubling production capacity.
• Led the Implementation of preventive maintenance programs, achieving less than 1% downtime and a 99% departmental satisfaction score through proactive planning, real-time maintenance tracking system, optimized spare parts inventory management, and efficient maintenance procedures to improve overall equipment performance, maintenance efficiency and reduced costs for the company reduce maintenance costs and time and additionally, managing and supervising the operation and synchronization of 1800KVA (2 generators) & 1250 KVA (3 generators) to ensure uninterrupted power supply.
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