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Muhammad Ali, Making Department Startup Leader

Muhammad Ali

Making Department Startup Leader·Procter & Gamble Louisiana USA

Pakistan

Diploma, Mechanical

Work experience

Total years of experience: 17 years, 10 months

Making Department Startup Leader

September 2025 - March 2026

Procter & Gamble Louisiana USA

Alexander City, United States

September 2025 - March 2026

1- Share global best in class practices for autonomous and progressive maintenance.
2- Accelerate the commissioning of “Fibers making department” & achieve the vertical SU goals.
3- Provide technical coaching to P&G Alexandria technicians on P&G Global standards
4- Provide hands-on training on-the floor to P&G Alexandria technicians on Autonomous
Maintenance standards (E.G Centerlines, Cleaning-Inspection-Lubrication, Defect Finding and
Fixing)
5- Provide hands-on training (both on-floor and in-room training) on Progressive Maintenance
standards (maintenance standards, maintenance process management)-
6- Provide hands-on training to review and correct equipment bill of materials.
Company industry:
FMCG

Technical Support Engineer

September 2022 - September 2025

Procter & Gamble

Pakistan

September 2022 - September 2025

Led a multi-disciplinary maintenance team to enhance plant reliability and operational stability.
- Spearheaded RCO (Rapid Changeover) system improvements across the site, reducing CO time by 30%.
- Delivered maintenance excellence and cost optimization through localization initiatives and time-based
maintenance (TBM) improving effectiveness by 40%.
- Ensured 100% compliance of operational in alignment with site Procter & Gamble IWS Phase 3 requirements.
- Recognized with CEO Awards (2022, 2024) for technical leadership and performance delivery.
Company industry:
FMCG

Lead Process Engineer

August 2019 - August 2022

Procter & Gamble

Karachi, Pakistan

August 2019 - August 2022

Improved production efficiency and reduced scrap levels to below 2%.
- Introduced P&D IWS & Six Sigma-based process monitoring for consistent quality.
- Achieved key process performance targets including (PR 80%, UPS 15%).
- Trained operators on IWS tools and autonomous maintenance routines.
Company industry:
FMCG

Team Leader

July 2016 - July 2019

Procter & Gamble

Karachi, Pakistan

July 2016 - July 2019

- Led shift team to achieve safety, quality, and production rate (PR) targets consistently.
- Managed shift manpower planning, overtime control, and team coordination to achieve operational goals.
- Increased production capacity from 2 to 5 sachet machines while reducing workforce requirements by 50%
- Introduced automatic case filling system and progressed line qualification to P&G AM- Step 3 model.
Company industry:
FMCG

Site Project Delivery Mechanical

October 2014 - June 2016

Procter & Gamble

Karachi, Pakistan

October 2014 - June 2016

1. Get the technical mastery on new machines, develop step up card and train operations before handover to department.
2. Make the Validation (IQ, OQ) protocols before starting commissioning & get approval from relevant departments.
3. Arrange meetings with Engineering & operations leaders & follow “Small Project readiness checklist” for small projects.
4. Developed Standards for new projects. (CIL, Centerlines, SOP, Troubleshooting guide, Safety Map, Critical spare parts list, etc.)
5. Perform IQ, OQ checks and compile the punch list items & hand over to engineering team.
6. Commission the machine as per PQ protocol, perform the TAMU checks and verify Quality results.
7. Track day to day results during ISU & then GPRM2 results.
8. Help the operations for achieving the target PR for the first month (ISU), Also help the operations team to get the seconds month PR on target (GPRM2)
9. Develop training material and qualify the operators.
10. Improve the machine life through Qualify new machines according to AM Step 3(Autonomies maintenance).
Company industry:
Consumer Packaged Goods Manufacture
Job role:
Manufacturing

Site Project dilievery Mechanical

October 2014 - June 2016

Procter & Gamble

Karachi, Pakistan

October 2014 - June 2016

1. Get the technical mastery on new machines, develop step up card and train operations before handover to department.
2. Make the Validation (IQ, OQ) protocols before starting commissioning & get approval from relevant departments.
3. Arrange meetings with Engineering & operations leaders & follow “Small Project readiness checklist” for small projects.
4. Developed Standards for new projects. (CIL, Centerlines, SOP, Troubleshooting guide, Safety Map, Critical spare parts list, etc.)
5. Perform IQ, OQ checks and compile the punch list items & hand over to engineering team.
6. Commission the machine as per PQ protocol, perform the TAMU checks and verify Quality results.
7. Track day to day results during ISU & then GPRM2 results.
8. Help the operations for achieving the target PR for the first month (ISU), Also help the operations team to get the seconds month PR on target (GPRM2)
9. Develop training material and qualify the operators.
10. Improve the machine life through Qualify new machines according to AM Step 3(Autonomies maintenance).
Company industry:
Consumer Packaged Goods Manufacture
Job role:
Manufacturing

Site Mechanical Start up Leader

October 2014 - June 2016

Procter & Gamble Pakistan

Karachi, Pakistan

October 2014 - June 2016

- Led successful validation and speed-up of VS300 & VS400 machines from 70 to 75 BPM.
- Led installation and validation of sewing technology machines, replacing cotton bags with poly bags, resulting
in significant cost savings.
- Led a Kaizen improvement on bag pressor operations, delivering significant packaging cost savings.
Company industry:
FMCG

Technical Planner

May 2014 - September 2014

Procter & Gamble

Manchester, United Kingdom

May 2014 - September 2014

Run the Proficy, line stops, and other reports at daily basis.
2. Highlight the major loss areas. & bring it to DDS meeting. Do why-why & root cause analysis.
3. Work on RTT (run to target process parameters) and daily Centerline tracking.
4. Plan and schedule the maintenance activity at daily basis.
5. Participate in the daily Pit stop and perform the Maintenance work, Participate in daily DMS.
6. Issue and return the parts replaced during pit stop and fill the PM cards.
7. Attend the "review meeting" and plan for the next day.
8. Review SAP on daily basis and release parts for TBMs (time base maintenance).
9. Plan PM and arrange resources.
10. Planning for upcoming Change over and print the Job Cards, also need to arrange the full support.
11. Highlight the major loss area on monthly basis and work on it to eliminate the problem
Company industry:
Consumer Packaged Goods Manufacture
Job role:
Maintenance, Repair, and Technician

Technical Planner

May 2014 - September 2014

Procter & Gamble

Nigeria

May 2014 - September 2014

1. Run the Proficy, line stops, and other reports at daily basis.
2. Highlight the major loss areas. & bring it to DDS meeting. Do why-why & root cause analysis.
3. Work on RTT (run to target process parameters) and daily Centerline tracking.
4. Plan and schedule the maintenance activity at daily basis.
5. Participate in the daily Pit stop and perform the Maintenance work, Participate in daily DMS.
6. Issue and return the parts replaced during pit stop and fill the PM cards.
7. Attend the "review meeting" and plan for the next day.
8. Review SAP on daily basis and release parts for TBMs (time base maintenance).
9. Plan PM and arrange resources.
10. Planning for upcoming Change over and print the Job Cards, also need to arrange the full support.
11. Highlight the major loss area on monthly basis and work on it to eliminate the problem.
Company industry:
Consumer Packaged Goods Manufacture
Job role:
Maintenance, Repair, and Technician

Technical Planner

May 2014 - September 2014

Procter & Gamble Nigeria

Nigeria

May 2014 - September 2014

1. Run the Proficy, line stops, and other reports at daily basis.
2. Highlight the major loss areas. & bring it to DDS meeting. Do why-why & root cause analysis.
3. Work on RTT (run to target process parameters) and daily Centerline tracking.
4. Plan and schedule the maintenance activity at daily basis.
5. Participate in the daily Pit stop and perform the Maintenance work, Participate in daily DMS.
6. Issue and return the parts replaced during pit stop and fill the PM cards.
7. Attend the "review meeting" and plan for the next day.
8. Review SAP on daily basis and release parts for TBMs (time base maintenance).
9. Plan PM and arrange resources.
10. Planning for upcoming Change over and print the Job Cards, Also need to arrange the full support.
11. Highlight the major loss area on monthly basis and work on it to eliminate the problem.
Company industry:
FMCG

commissioning engineer

July 2012 - April 2014

Procter & Gamble

Nigeria

July 2012 - April 2014

1. Perform the Yellow Lining (Electrical Schematics) of the Line VS Standard.
2. Check all CPE (centerline) Tasks in the Area and adjust to target.
3. Check the line for any defects and perform the CIL tasks, replace the part if required.
4. Make sure that all Lube connection, Glycol connections, and pneumatic connection are routed per standard, fix any leakages and defects.
5. Check the machine parts according to required size and perform the Changeover tasks for the Area.
6. Complete Static & Dynamic checks.
7. Web up the Material and start up the Line, observe for web mistakes, vibrations, heat up parts, wrinkles or any abnormal sound and defects.
8. Check all Quality Parameters and run line for first 15 minutes.
9. After the results from Lab if it passes do the quality checks for initial 15 minutes run, then run the Line for 24 Hours run and wait for the Lab results.
10. If the product passed the quality parameters in Lab, then to Hand Over the Line to ISU Team (CQV team members help ISU for few days until Line is stabilize)
Company industry:
Consumer Packaged Goods Manufacture
Job role:
Maintenance, Repair, and Technician

Commissioning expert

July 2012 - April 2014

Procter & Gamble Egypt

Lagos, Nigeria

July 2012 - April 2014

- Executed pre-commissioning and commissioning tasks to ensure safe start-up.
- Conducted functional testing, loop checks, and system integration against design requirements.
- Coordinated with engineering, vendors, and operations to resolve issues and close punch lists.
- Completed commissioning documentation and supported smooth handover to operations.
Company industry:
FMCG

Technical Support Group

February 2011 - June 2012

Procter & Gamble

Nigeria

February 2011 - June 2012

1. Working as a Matrix leader for Area 4. Support Operation in trouble shoots the problems.
2. Rapid Change Over owner in Area 4. (Reduces the change over time from 110 minutes to 45 minutes and sustain the result for each change over. Successfully reduced the losses after changeover.)
3. Train Operators on process and trouble shooting skills.
4. Define AM, PM, TBM, CBAs and CIL, Procedures for operations.
5. Investigate the top loses across the lines on daily basis and define the route cause through 6W2H, why-why analysis, fishbone diagram.
Company industry:
Consumer Packaged Goods Manufacture
Job role:
Maintenance, Repair, and Technician

Technical Support Group

February 2011 - June 2012

Procter & Gamble

Nigeria

February 2011 - June 2012

1. Working as a Matrix leader for Area 4. Support Operation in trouble shoots the problems.
2. Rapid Change Over owner in Area 4. (Reduces the change over time from 110 minutes to 45 minutes and sustain the result for each change over. Successfully reduced the losses after changeover.)
3. Train Operators on process and trouble shooting skills.
4. Define AM, PM, TBM, CBAs and CIL, Procedures for operations.
5. Investigate the top loses across the lines on daily basis and define the route cause through 6W2H, why-why analysis, fishbone diagram.
Company industry:
Consumer Packaged Goods Manufacture
Job role:
Maintenance, Repair, and Technician

Technical Planner

December 2009 - January 2011

Procter & Gamble UK

Manchester, United Kingdom

December 2009 - January 2011

Analyzedailyprocessparameters, BreakDowns&Keyloss, makecorrecting&preventiveplans.
-Planning&SchedulingofPitstopactivities, ChangeOvers&PreventiveMaintenancetasks
-SupportContinuousimprovementbyraiseKaizenChangeControls&executetheimplementation.-Developed&deployednewareastandardstotheteam&updatetheskillblocksaccordingly.
Company industry:
FMCG

Area 1 Technician

June 2009 - November 2009

Procter & Gamble

Manchester, United Kingdom

June 2009 - November 2009

Learn the diaper process for self and make OPLs to teach others
2. Perform daily RLS and CIL tasks.
3. Help the area 1 operator in normal operations.
4. Check the process parameters and update in proficy
Company industry:
Consumer Packaged Goods Manufacture
Job role:
Maintenance, Repair, and Technician

Shift Technician

June 2008 - May 2009

P&G

Karachi, Pakistan

June 2008 - May 2009

1. Plan operation as per production numbers and initiate PDR (Production Direction Report)
2. Manage contractor workforce and ensure availability.
3. Technical support to the running line.
4. Condition based maintenance.
5. Conduct process audit as per requirement.
Company industry:
Industrial Production
Job role:
Maintenance, Repair, and Technician

Education

Pak swis training Center

September 2008

September 2008

Diploma, Mechanical

Pakistan

Ranked in top 18 students out of 66, awarded special diploma of Dies & Mould.

Skills

Maintenance Planning

Expert

Troubleshooting

Expert

Commissioning

Expert

Technical Support

Expert

Team Handling

Expert

Commissioning Skills

Expert

Production

Expert

Maintenance

Expert

Commissioning

Intermediate

Maintenance Engineering

Intermediate

Maintenance Planning

Expert

Troubleshooting

Expert

Technical Support

Expert

Team Handling

Expert

Languages

English

Expert

Arabic

Beginner

Urdu

Expert

Hobbies and interests

Fitness Excercise

"P&G fitness comptetion 2015" runner up award.