Operational Excellence Analyst
Farabi Petrochemicals Company
Total years of experience :22 years, 7 Months
Develop the OPEX model and lead the operational excellence for Key success factors of business in the areas of Manufacturing Excellence, Assured Quality, and People Excellence.
Analyzing & identifying key projects & strategic initiatives, cascade the leading KPIs & lagging performance indicators and ownership through Balance Score Card, Review the progress, results and adjust through countermeasures.
Managing six sigma projects to improve quality, reduce cycle time, cost and to achieve customer satisfaction.
Institutionalizing Six Sigma & Lean culture by trained the employees on Yellow & Green Belt trainings.
Conducting periodical reviews of the six sigma project with the management committee & project team.
Conducting the Internal Audits to ensure the compliance and effectiveness of the company management system.
Facilitate the root cause analysis studies and publish the monthly status of RCA recommendations to the management.
Quality, Health, Safety & Environment (QHSE)
Design, develop and implement Farabi Integrated Management system (based), which is based on the requirements of international standards like ISO9001:2008, ISO14001:2004, OHSAS 18001:2007 and RC14001:2008 (Responsible Care, RCMS).
Prepare the annual internal QHSE audit program, carry out and co-ordinate the Internal Audits to ensure the compliance and effectiveness of the company management system.
Manage the non-conformance process for effective resolution and process improvement. Analyze the corrective actions for bottlenecks, backlogs and procedural gaps and ensure that corrective & preventive actions are effectively implemented.
Manage the FIMS documentation and records processes to ensure the effective implementation and sustenance of FIMS management system.
Liaise with the external assessment body on all matters related to the external accreditation and certification of ISO 9001, ISO14001, OHSAS 18001 & Responsible Care.
Planning and evaluation of process optimization strategies to ensure that company policy objectives and work plans are measured and analyzed for further continual improvement actions.
Review the performance of the Management Systems at planned intervals to ensure its continuing suitability, adequacy and effectiveness.
Organizing and co-coordinating management reviews and QHSE periodical meetings.
Conducting Safety risk assessment & environmental aspect impact studies for Farabi processes.
Implementing Q-Pulse Compliance Management system for Document Control, Audit and Corrective/Preventive Action (CA/PA) module.
Develop & Conducting QHSE & Root Cause analysis trainings session for employees.
Six Sigma & Lean
Institutionalizing Six Sigma culture by trained the employees on Yellow & Green Belt training's.
Facilitating the functions to identifying the chronic issues to initiate the six sigma projects.
Conducting periodical reviews of the six sigma project with the management committee & project team.
Ensuring the timely completion of the six sigma projects.
Implementing 5S work place and visual management system.
Conducting trainings on 5S work place management system.
Business Strategic Management / Balanced Score Card
Participating in the development & reviewing of company strategy (including Vision, Mission, Strategic themes, values, objectives & targets).
Formulate strategic objectives, measurements, targets, and initiatives in coordination with concerned managers.
Cascade approved Balanced Scorecard to all the concerned managers and implement it in ERP.
Identify and establish the strategic objectives, targets & programs at company & department level based on the concept of Balanced Scorecard.
Conduct strategic performance review meeting every quarter. Identify gaps, assign responsibilities to Managers for root cause analysis and corrective actions to be taken.
EFQM-Self Assessment
Leading & Conducting the self-assessment of the organization based on EFQM Model 2013.
Preparation of self-assessment report (EFQM) and present the audit strengths & weaknesses to the management committee.
Follow-ups with the departments to close the gaps of the self-assessment report (EFQM).
Quality, Health, Safety & Environment (QHSE)
Developed integrated business management systems (IBMS) based on the requirements of International standards like ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007.
Conducted Site Governance and Compliance Audits as per the requirement of the clients.
Developed Quality Dashboards & Review frameworks.
Carried out Risk Mitigation for site with abatement plans as per EHS requirements.
Conducted Customer Satisfaction surveys and closed the gap areas with the delivery team.
Developed Supplier management evaluation system.
Six Sigma & Lean
Developed & implemented six sigma policy.
Established and implemented six sigma methodologies for improved business performance.
Imparted training on six sigma (Yellow & Green Belt).
Developed online training module for six sigma Yellow belt trainings.
Quality, Health, Safety & Environment (QHSE)
Maintained "ZERO Defects & RFT" as a quality absolute for all the finish goods / intermediates products by implementing the Quality Rating Index system.
Implemented ISO 9001:2008 QMS & ISO 14001:2004 EMS system.
Conducted Process cum product audits (PCPA), Process Audit & vertical audits to strengthen the system.
Assisted Supply Chain in developing vendors & provide support to Raw & Packing Material vendors towards meeting company’s requirement.
Design & developed corporate quality performance reports for Management Review.
Assist local management in the preparation and presentation of QHSE meetings.
Statistical analysis of the processes & products and shared with the management committee in review meetings.
Quality, Health, Safety & Environment (QHSE)
Conducted inter departmental QHSE audits to streamline the management system in the organization.
Conducted Risk Assessment, Environmental Aspect impact, & COSHH studies.
Conducted Process cum product audits (PCPA), Process Audit & vertical audits to strengthen the system.
Reviewed design of new formulations for the shop floor & to co-ordinate with Research & Development function to resolve the issues in design review stage.
Analysis the data of raw materials, Resin & Emulsion, Packing Material & Finished Goods by using statistical process control.
Reviewing design of new formulations for the shop floor & to co-ordinate with Research & Development function to resolve the issues in design review stage. Actively involved in trend analysis of batches for enhancement of formulation and properties.
Analysis of Non-conformity product to understand the issues related to polymerization, pigmentation, exothermic reaction mechanism & solvent viscosity.
Monitored quality improvement through Quality Rating Index (QRI) and Right First Time (RFT) concepts.
Implemented SAP Quality module in the quality lab.
Six Sigma & Lean
Responsible for the Six Sigma projects identification and execution for Quality assurance (QA) & Environment treatment plan (ETP) department.
Imparted awareness training on Six Sigma yellow and Green Belt.
Conducted the process capability studies for the raw materials & finished products and shared the results with the vendors as well with the internal customers.
Certified Lead Auditor ISO 14001:2004
Certified Lead Auditor OHSAS 18001:2007
Certified manager of Quality/ Organizational Excellence (CMQ/OE)
Certified International Projhect Manager (CIPM)
Lead Auditor - ISO 9001:2008
Certified Six Sigma Master Black Belt (CSSMBB)
MBA in Operation Management
Master of Science (MSc) in Chemistry