Production & SHEQ Manager
Doshi & Co. (Hardware) Ltd.
Total years of experience :13 years, 6 Months
Management Representative during successful ISO 9001:2015 Transition / Surveillance Audit in May 2018 and Re-certification Audit in Dec 2019.
Re-constituting Safety Committee and formulating its mandate for the division.
Streamlining labour allocation on Production floor to optimize Labour costs; ensuring Pre-Authorization of allocated Overtime, transparency in recording of Overtime and effective adherence to utilisation of Biometric system yielding attendance registers providing effective control of labour resources
Key Responsibilities:
Co-ordination with the sales team to ensure proper planning of production according to the generated orders by maintaining
production control records
Providing information to sales team and Management pertaining delivery dates, schedules and operating constraints
Taking ownership of jobs, Works orders, WIP stock
Monitoring the full compliance of Works orders use; work in progress, maintaining order and discipline in production process
and reporting any occurrences or problems to the General Manager
Monitoring all the scrap generated from the manufacturing processes and ensuring that it is minimized
Compiling and presenting daily and weekly production reports
Overseeing allocation of duties for each staff in the production area through staff scheduling, casual employee uptake and overtime to ensure that resources are well utilized
Ensuring that all health and safety requirements are adhered to in all production areas and facilitating training on safety and machine operations
Overseeing overall cleanliness and orderliness in all production areas
Planning and budgeting for raw materials that will be needed for future production
Responsible for QMS compliance within the division
Updating and maintaining weekly production schedule
Monitoring quality, accuracy and timeliness of all orders to ensure commitments are met through production of high quality products meeting customer expectations
Ensuring stock taking is facilitated by the production team as scheduled by Internal Audit and accurate inventory records are maintained
Liaising with Maintenance Manager to ensure preventative maintenance of all production equipment
Assisting the costing department with estimation to ensure the pricing accuracy of all job orders
Conducting manpower planning for the production department to ensure adherence to budget and achievement of labour efficiency
Assisting the Management in the recruitment of competent and productive production team
Overseeing all Safety Steering Committee imperatives
Overseeing Quality Assurance analytical procedures and ensuring prompt provision of Analytical & Technical Test Certificates to Customers upon request.
Initiating and driving a sustainable SHE system based on a roadmap to attaining continued improvement in operational SHE metrics and eventual readiness for potential OHSAS Certification
Continuous reduction and prevention of incidents meeting set KPI targets:
- Consistent Reduction in No. of Total Reported Accidents YOY; From 346 in FY 2014 to 225 in FY 2015 to 177 in FY 2016 to 80 in FY 2017
- 100% Timely Closure of Evaluated High Risk Hazards outlined within EOSH Risk Register (within a week of Observation and Reporting)
Imparting relevant Behavioural Safety techniques on shop floor personnel as Change Management initiative; in particular to Lift Truck, Pallet truck and Tractor Operators, Goods and Material Loading & Dispatch Supervisors, Packaging Machine Operators, First Aiders, Janitors and Gardeners, Boiler Operators, Stock-keeping Clerks, Manual Loaders/Off loaders, Quality Control Analysts.
Solid Waste Segregation & Disposal:
-Sensitization and Awareness Creation for all employees and contracted staff
-Provision of Colour-coded bins at strategic points for segregated solid waste collection
-Revamping of Existing Non-Hazardous Waste Collection Shed and Erection of a Hazardous Waste Shed
Intervention in the monitoring of microbiological analysis of potable water within the organization following noted deviation from acceptable requirements; coordinating external qualitative analysis of water samples from 3 sources (Borehole, EPZ and RO permeate) and eventually isolating borehole distribution system due to non-conformance to drinking water quality standards. Revision of potable water tank cleaning procedures, introduction of water tank sanitation procedures and subsequent training on the same for cleaning team personnel and QA analysts
Creation of a Master Identification List for all Fire Protection Equipment and Accessories (above 400 in number), allocation of easy identification coding at the point of placement
Key Responsibilities:
Assuring compliance to OSH Act 2007, FOOD, DRUGS & CHEMICAL SUBSTANCES Act 2012, EMCA 1999/2009 and applicable regulations
Active involvement in QMS Procedural & Document Review
Representing the management during QMS & HACCP certification surveillance audits
Aligning with Factory Manager and Technical Director on SHE objectives, strategies and KPIs and cascading them to Departmental Safety Sub-committee representatives
Overseeing all Safety Steering Committee imperatives
Scheduling and co-ordinating QMS Internal Audits and tracking follow-up corrective actions
Compiling an annual Financial implications report pertaining Cost of Safety (an initial Business Case for OSH entailing direct and indirect costs associated with accidents and significant illnesses occurring during financial year within the Company)
Ensuring continuous reduction and prevention of incidents meeting set targets; maintaining Hazard Register, Accident Register and files, spearheading Accident and Near-miss reporting and investigation, corrective action tracking
Scheduling and conducting QEOSH awareness training for contractors, Behavioural safety training for shop-floor personnel and safety induction for new employees
Conducting formal and on-job training on 5S and its implication in Safety Management
Re-initiating and upholding safety compliance systems including Risk Assessments, Permit-to-Work, Lift-truck Inspections, Pedestrian Gangways, regular First-Aid kit audits
Stack/Flue gas emissions monitoring, Dust Load & Noise Survey monitoring to ensure compliance to below threshold values
Driving Waste Management to reduce the organization’s environmental impact using 3R principle
Overseeing Waste segregation, disposal and associated statutory compliance
Representative on all matters pertaining Fire Safety
Initiating, training on, implementing and maintaining 5S principles within the Baking powder department; reduced congestion, improved ventilation, enhanced tools access, increased goods-holding space.
Introducing Kaizen activities to yield cleaner and enhanced Production outputs in Food Processing departments; colour-coding of lubricating points in packaging machines, fixed placement of sieved collecting troughs for powder and packaging material rejects to enhance rework speed.
Attaining average monthly Productivity targets of above 95% for Baking Powder Plant, 92% for Detergent Plant
Attaining Quality Objective of reduced packaging / wrapper waste / rejects from packaging machines via strict adherence to Planned Preventive Maintenance schedule
Conducting Training gap-analysis for all personnel groups and effectively undertaking on-job training for relevant personnel in OHS aspects, QMS and HACCP basics, Preventive Maintenance.
Key Responsibilities:
Managing daily production requirements and outputs; materials planning and reservations, finished goods holding and dispatch (on the production floor and within SAP ERP)
Attending to any corrective maintenance promptly to minimize production loss and improve machine efficiencies
Organizing and maintaining the preventive maintenance schedule for each equipment and ensuring completion of maintenance orders raised (on the production floor and within SAP ERP)
Ascertaining and requisitioning spares required and checking the quality of spares received to ensure corrective/preventive maintenance can be undertaken promptly
Implementing the quality management system; ISO 9001:2008 and food safety system; HACCP / ISO 22000:2005, as applicable in the department
Understanding, pro-actively managing and delivering on client expectations and needs. Major Client entities served included: Grain Bulk Handlers Limited Group, Rea Vipingo Plantations Ltd. Group, KenFreight (EA) Ltd., Kenya Petroleum Refineries Ltd., Boss Freight Terminal Ltd., Baobab Beach Resort Ltd. and Great Lakes Ports CFS Ltd.
Enterprise Risk Services (ERS) - Following the exclusive contract between Deloitte and Coca-Cola Central, East & West Africa Limited to provide Cooler Asset Verification Consultancy services for Coca-Cola across 10 countries in Africa, was assigned to undertake the exercise scoping the Kenyan Coast - Far North locations entailing Malindi and its environs - the sample size being 167 coolers, the entire sample for Coastal region being approximately 515 in number.
Key Responsibilities:
For assigned audit file sections during an audit engagement, performing audit procedures responsive to the assessed risks of material misstatement at assertion level while maintaining focus on audit quality. Documenting work done on assigned audit areas by ensuring compliance to relevant methodologies and the Deloitte Audit Approach.
Spearheading a multi-disciplinary Total Productive Management (TPM) - Operational Excellence Performance Improvement project: Improvement of Plant Carbon-dioxide yield (entailing 6 bottling lines) from mean of 43% to 60% yielding an estimated annual saving of above KSH. 50, 000, 000
Formulating and co-ordinating Kobetsu Kaizen (Focused Improvement) initiatives for process performance enhancements:
Carbonation process performance on Bottling Line 8 to attain Ppk target of 1.3
Reduction of Glass Breakages at Bottling Line 8 Empty Bottle Collector
Water and Microbiological analysis (water treatment process capability and performance). Identifying bottlenecks within the separate Treated Water distribution pipeline networks for Beverage Manufacturing Process and Steam Generation, and providing lasting solutions for streamlined supply
Key Responsibilities:
Thorough orientation to carbonated beverage and stills bottling process units and typical operations; continuous interaction with equipment service specialists (KRONES)
Active participation in Food Safety - FSSC 22000 - surveillance audit; validating plant Good Manufacturing Practices (GMP) audit results and ensuring system documentation compliance
Auditee during Quality Management System - ISO 9001 - Re-certification Audit and during Integrated Environment and Occupational Safety and Health (EOSH) - ISO 14001 & OHSAS 18001 - Management System Surveillance Audits
Process Data analysis and Statistical Process Control using Infinity QS SPC software
Enforcing PPE compliance, accident reporting, investigation and analysis, conducting awareness training for contractors and safety induction for new employees
Overseeing Waste segregation, disposal and associated legal and systemic compliance
Coordinating Internal Audits/Monthly safety inspections, fire protection equipment inspection and statutory equipment examination diligence
Updating Manufacturing and Sustainability Dashboard, System Performance Trackers; monthly and annual Environmental Performance Measurement (EPM) report and online Group EPM dashboard
Validating Quality inspection methods and procedures for raw materials and primary packaging; closures, preforms, labels, Nitrogen and Carbon-dioxide.
Conducting Health and Safety Risk assessment and updating the risk register as and when required
Preparation, availing and updating of TPM SHE pillar board as visual tool for SHE initiatives, activities and functions
GMP and Site 5S (foundation pillar of TPM) audits for conformance to relevant standards
Project team member for water treatment unit (KROFTA) modification to enhance white water recycling rate
Conducting team-based research on product development; launching of New Brands of toilet tissue, paper towel and paper
barrel in conformance to new East African Standards
Key Responsibilities:
Approval or rejection of starting materials, packaging materials, and intermediate, bulk and finished products in relation to
their specifications
Validations of analytical procedures and calibrations of control equipment
Advocating for thorough internalization of Quality Management System - ISO 9001
Generating a monthly yield inferential analysis report from daily production reports
Process and Production Intern
Manufacturing Intern
Operations and Process Technology Intern