Senior Specialist Engineer – Operations/Process Engineer
Arcelik Global
Total years of experience :6 years, 5 Months
Plan production according to raw material availability.
➢Lead complete range of washing machine production team (20% of overall business) to achieve day-to-day production KPIs. (Safety, MHPU, CC, 5S and IMS).
➢Engineering Support to develop Production KPIs system for Washing Machine Assembly line.
➢Implement Lean Manufacturing concept for TPM and 5S implementation at assembly line.
➢Develop WIS and apply continuous improvement practice to optimize production practices.
➢Asses WIP and set standards for WIP stocks with implementation of inventory management concept.
➢Complete revamping of Screen-Printing area and enhance productivity by 15% by reducing NPA. (PKR 0.3 m/yr)
➢Reduction of absenteeism loss from 5.6% to 4% through implantation of six sigma. (PKR 1.4 m/yr)
➢Reduction of FMD process rejection by 50% through implantation of six sigma. (PKR 5.8 m/yr)
Midas Safety is a leading private label supplier of safety products to more than 50 countries in the world headquartered in Canada. We have factories in multiple locations within Asia proving best class hand & body protection solutions to their B2B customers all around the globe with investments in modern and efficient manufacturing plants, logistics and warehouses and vertical integrated value chain. Departmental Lead - Operations/Process Engineer Aug'2021-Jun'2022
➢Responsible for planning and execution of production to ensure timely completion of shipments.
➢Responsible to update priority matrix and assign tasks to team according to their skills and competence.
➢Responsible for ISO, MSM, safety audit compliance and provide root cause against each observation.
➢Converted conventional covering machine with Servo driven to reduce changeover by 90%. (Estimated saving $ 4, 500/yr)
➢Got 8 times 'Employee of the month' recognition in a year.
➢Take part in business KPI making process and yearly targets.
➢Responsible to track training and development of complete operations department.
- Responsible for planning of more than 500 SKUs, ensuring 100% capacity utilization by aligning RM demands.
- Responsible for the designing the corrective/preventive action against the point highlighted through audits, customer complaint, MSA's and from any other improvements projects.
- Reduced changeovers from 150 to 110 per month and reduced excess production from 20% to 3% by doing project 'Resource Bonding', 'PVA checklist' and 'Visual Management'
- Reduced departmental rejection by 26% through six sigma implementations. saved $885/month.
- Selected as Kaizen Champion for Operations Department
- Develop operations performance dashboard through BI for monitoring and control.
- Digitalization by replacing paper sheets through online entry and link data through online portal for live data.
- Part of a change management activities and projects through discovery, design, and implementation of lean and six sigma strategies to translate the transformational vision into specific goals and priorities by Business Process Engineering, Hoshin Kanri, PDCA, VSM, 5S, 5-Why, TPM, FMEA, Gemba, Kaizen and Control Plan.
- Develop FMEA for all high value products to identify the parts of the process that are most in need of change.
Successfully completed project "Lean Management in Material Handling & Transportation", 50% improvement through lean and chute fabrication, saved $1185/month.
➢Build Kaizen mechanism and 5-S by implementing R&R method.
➢Reduced 86% paper consumption through revamping and online entry.
➢Initiated a project on visual management, formed on going project board and apply Andon in several places to maintain WIP.
➢Made Video based departmental orientation and video-based training.
Managing process & production plan with optimum utilization of resource/capacity. Maintaining production schedule.
➢SAM based line balancing to get the maximum possible output.
➢Application of Lean tools for productivity improvement, design VSM for all SKU's and layout of each line on the basis of balanced line.
➢Interacting with the production floor to resolve manufacturing issues and defects by optimizing current process
Increment in the productivity by drawing a current state and a future state map. Improved the existing layout by propose an optimize one for minimizing the bottlenecks of the process. Simulation on Witness-System Simulation
