Group QA Manager
Al Nafees Holding Co.
Total years of experience :29 years, 4 Months
Responsibilities:
Involved in company’s strategies development and implementation of set goals and strategic objectives.
Applied KAIZEN, a problem-solving methodology addressing issues and problems in the working environment including work processes and procedures. Solved small issues (Small KAIZEN) and large issues (Large KAIZEN). Checked effectiveness of measures and standardized the processes/procedures.
Planned and developed ISO QMS policies and procedures for two of its subsidiaries and directed the implementation & maintenance of Quality Management System.
Developed next level SOPs, Work Instructions and Quality manual organized awareness training and ensured proper implementation and reported on its effectiveness to senior management.
Arranged third party audit and obtained certification by accredited certification bodies for two subsidiaries of Nafees Holding against ISO 9001:2015 requirement.
Managing supplier prequalification, closing of process and system non-conformity, through proper root cause analysis and effective connective & Preventive action.
Handling and closing of customer complaints and taking required corrective and preventive actions.
Planned and executed QMS audits (internal, external and customer audits) and monitoring implementation of recommended improvement actions, corrective & preventive actions addressing non-conformity.
Responsibility:
Supervise the implementation & maintenance of Quality Management System across all five ABB entities & operations in KSA and report on its effectiveness to the top management.
Manage all aspects of planning, scheduling & execution of internal & external QMS audits and monitor implementation of effective corrective & preventive actions addressing non-conformities.
Lead investigation into quality problems to identify & analyze root causes and ensure remediation through corrective & preventive action plans.
Establish & monitor achievement of quality objectives based on key performance indicators (KPI) covering all key functions/processes of the QMS.
Coordinate with process owners & operating staff to improve processes through programs for updating & reengineering relevant procedures.
Unify all main processes of 5 legal entities of ABB in Saudi Arabia to reduce paperwork and deliver SLIM requirements.
Develop & maintain a framework to facilitate upcoming & planned new facilities in KSA in completing all requirements for and securing ISO 9001:2008 certification.
Support new facilities in defining & developing procedures & instructions for new facilities and coordinate internal & external audits to obtain QMS certification.
Organize & conduct Quality Management Review sessions to analyze findings & results of various surveys & audits - customer complaint resolution process (CCRP), Net Promoter Score (NPS - customer feedback), internal & external certification audit reports - to assess status of achievement of quality objectives, product non-conformities & improvement action plans. Report outcomes to management and drive implementation of required corrective & preventive actions.
Promote ‘operational excellence’ (OPEX) by implementing ‘4Q’ (4 Quadrants; Measure, Analyse, Improve, Sustain) an ABB’s data driven problem-solving process, delivering periodic 4Q training to teams, posting 4Q projects of ABB SMT database & OPEX Analyzer and developing required documents & records.
Facilitate continuous improvements in health & safety performance by contributing to the implementation of Saudi Plus an ABB initiative for continuous improvements in the health & safety program
Monitor & support activities related to ‘Manufacturing Operations Maturity Assessment’ (MOMA) in each section of ABB in KSA.
Write various technical & management system reports as per company requirements.
Plan, execute & monitor activities related to the ‘Supplier Qualification Process’ (SQP) in coordination with SCM & technical teams ensuring compliance with ABB Group standards & guidelines. Conduct prequalification & process audits of suppliers, evaluate prequalification performance and prepare reports recommending appropriate qualification action for approval of the top management/Group SCM.
Coordinate with the supply chain management (SCM) team and ensure completion of Supplier Performance Evaluation (SPE) of suppliers based on parameters set out in ABB Group supply policy & guidelines.
Support ABB business units in completing required actions to implement recommendations of group audits, customer audits & OPM audits.
Highlights
Mapped business processes of 5 separate ABB legal entities in Saudi Arabia and reengineered processes consolidating 50 processes in to 10 process documents.
Supported newly established facilities - HV GIS & DMMG workshops - in preparing all required documentation and successfully obtaining ISO 9001:2008 certification.
As a 4Q Certified Trainer/Coach, trained 5 batches of 10 employees each in utilizing 4Q in problem solving & continuous improvement projects.
Led the program for successfully obtaining OSHAS 18001 safety & health system management certification for various units.
Process Owner for six years of "Maintain Quality Management System" at country level.
Lead the internal audit team of twenty auditors across ABB Saudi Arabia.
Responsibilities
Led the establishment of Quality Management System (QMS) in the organization and managed action plan for obtaining certification.
Dealt with customer feedback and coordinated with appropriate departments in prompt resolution of customer complaints.
Trained employees on ISO 9001:2008 standard and in developing required documentation & procedures.
Highlights
Established the company’s QMS from scratch, prepared all documentation including Quality Manual, policies, procedures, work instructions & forms and successfully obtained ISO 9001:2008 certification.
Established the company’s customer complaint management system for effective & satisfactory handling & resolution of complaints and improving customer satisfaction.
Responsibilities:
Managed all aspects of quality including ISO 9001:2000 QMS, quality assurance, quality control & documentation, vendor/supplier quality assurance and complaints management.
Supervised the operation of the QC lab for conducting tests of raw materials, in process & finished goods and preparation of QC documentation.
Planned & executed various chemical analytical tests using modern instrumental & conventional methods ensuring compliance with standard procedures for despatch of defect-free products to customers.
Developed & implemented standard sampling & inspection plans for incoming, in process & final inspection and analytical test methods for raw materials & finished products.
Coordinated & managed maintenance and calibration of all laboratory equipment & instruments.
Conducted monthly evaluation of laboratory test data to identify trends in quality issues and implemented effective corrective & preventive actions.
Managed the process of investigation of customer complaints related to quality, identification of root causes & remediation in coordination with sales & marketing department and the customer.
Supervised the QA/QC team ensuring compliance with all applicable company policies & procedures.
Highlights
Set up the QC Analytical lab and developed & validated required analytical test methods for raw materials & finished products.
Mapped, reengineered & improved 5 key processes of the company.
Responsibilities:
Managed the operation of the modern QC lab equipped chemical & physical test equipment including gas chromatographs & tensile testing machines for conducting a wide range of tests to assure quality of raw materials, in-process goods and finished products.
Managed quality control activities including testing of incoming raw materials including BOPP & PE films, paper boards, inks, solvents & adhesive as well as in-process & finished products including PP & PE extrusion, flexible packaging, duplex packaging and commercial printing.
Supervised tests on samples provided by customers in order to develop matching specifications of products to meet customer requirements.
Led R&D efforts for upgrading quality of existing products and developing new products as per customer requirements.
Administered the company’s Quality Management System meeting requirements of ISO 9001:2000 certification.
Organized & supervised internal audit programs and implanted corrective & preventive actions for non-conformances.
Dealt with all aspects of vendor/supplier quality assurance & customer compliant handling.
Highlights
Implemented statistical process control tools & techniques and reduced non-conformances & production wastes by over 60% on a year-on-year basis.
Reduced customer complaints & cost of poor quality by 50% by eliminating barriers to production consistency through QMS & SPC implementation.
Asst. QA/QC Manager- May 2001-February 2005
Responsibilities:
Managed all aspects of quality including administration of QMS, production QA/QC and customer QA/QC.
Coordinated activities of the QC lab including development of test methods for raw materials, in-process goods and finished products as per applicable standards.
Supervised all laboratory physical & chemical tests and in-process inspections to ensure quality of PVC compounds and finished plastic products.
Participated in evaluation of compound formulation & preparation of cost estimates to quote competitive prices against customer enquiries.
Supervised test & analysis of customer samples and modification of PVC formulation to deliver product matching customer specified properties.
Coordinated with customers for approval of new products from blow moulding, injection moulding & extrusion moulding lines.
Supervised & coordinated maintenance & calibration of laboratory equipment & instruments.
Collaborated with clients to understand & provide viable solutions to their issues related to product quality & inconsistencies.
Highlights
Led the end-to-end process starting from scratch and obtained ISO 9001:2000 QMS certification for Arabian Plastics Compounds Co, a leading manufacturer of PVC compounds in the Middle East, owned & managed by SPF.
Established the laboratory at the PVC compounding facility with all required equipment, processes & procedures to undertake all QC and R&D activities.
Executed a program for optimizing grades & utilization of PVC compounds delivering significant reduction in raw material costs.
QA Engineer/Lab in-Charge Jul 1996 - Apr 2001
Responsibilities
Developed & implemented laboratory test methods for various products as per customer’s specifications & requirements.
Trained QA & production staff and supervised implementation of statistical process control (SPC) methods.
Assisted production department in controlling processes including blow moulding, injection moulding & extrusion using SPC tools & techniques.
Characterized properties of thermoplastic materials based on specified parameters including tensile strength, compression strength, strain, shear & stiffness, impact strength, tear & hardness.
Established test methods & conducted environmental & accelerated aging tests for materials & finished products.
Coordinated inspection & lab tests of incoming raw materials to ensure conformity with order specifications and coordinated with suppliers for resolving quality issues.
Verified quality of packaging products & precision engineered parts ensuring adherence to quality standards at all stages of production.
Participated as an auditor in several schedules of internal audits for ISO 9001 QMS.
Highlight
Participated in developing SOPs & manuals for implementing HACCP & ISO 14001 EMS standards.
Improved quality performance by introducing dock audit inspections and Six Sigma tools for process control substantially reducing customer complaints, cost of poor quality and process waste.
Executed projects through standard CQV procedure and developed new products for leading FMCG companies including Procter & Gamble, Bizagr Unilever & Jergens.
Responsibilities
Managed quality control in the water treatment plant by analyzing composition of intake water including detection of toxic heavy metal pollutants using atomic absorption spectrophotometer.
Supervised operation of the reverse osmosis (RO) plant for production of permeate water for further treatment & bottling for sales and preservation of the membrane system using specified chemicals.
Conducted bacteriological tests of processed drinking water for presence of pathogen like E coli, bacilli, yeast & moulds.
Participated in implementing test standards & statistical techniques for improving quality.
Supported production department in implementing SPC techniques for process control of water processing & purification plant as well as the packaging line with blow moulding, injection moulding & extrusion equipment.
EDUCATIONAL CREDENTIALS 1991 Ph.D. Chemistry, Aligarh Muslim University, Aligarh, India 1988 M.Phil. Chemistry, Aligarh Muslim University, Aligarh, India 1985 M.Sc. Chemistry, Aligarh Muslim University, Aligarh, India 1982 B.Sc. (Hons.) (Chemistry), Aligarh Muslim University, Aligarh, India ---------------------------------------------------------------------------- Ph.D. Title: “Physico- Chemical Studies of Inorganic Ion Exchangers and their application in the Analysis of Rocks, Minerals and Pharmaceuticals”. 5 years of research, worked on the analysis of Rocks, Minerals and Pharmaceuticals using modern analytical instruments. Extensively used the plethora of modern instrumental techniques like, Gas liquid, Chromatography (GLC), High performance liquid Chromatography (HPLC), Atomic Absorption Spectroscopy (AAS), Flame Photometry, Thermo gravimetric Analysis (TGA), DTA and Differential Scanning Calorimetry (DSC), Mass Spectroscopy, Infra-red Spectroscopy etc