Industrial Performance Coordinator & Factory Goal Alignment Pillar Leader
Nestle Pakistan Limited
Total years of experience :14 years, 4 Months
I am wearing two hats, one part of job includes leading Nestle Continuous Excellence GOAL ALIGNMENT, the foundation of TPM & Lean, i.e. Training, Coaching & assessment of whole factory. Additionally I am a member of FOCUSED IMPROVEMENT and EDUCATION & TRAINING Pillars.
Second part of job role is looking after INDUSTRIAL PERFORMANCE OPTIMIZATION, responsibilities of which include:
-Carrying out factory production CAPACITY SIMULATION of factory to optimize investments and avoid production short fall considering production volumes, line efficiencies, downtimes, and speeds etc.
-Making of LINE LABOR & ENERGY STANDARDS in liaison with production and engineering teams for every SKU on every production line of the factory, which includes line efficiencies, planned downtime details, no of employees and position of employees of the line, electricity & steam consumption details etc, providing support in budgeting the variable costs of the factory according to these requirements for next year, by uploading this information in SAP, and then evaluating and reporting the actual variances against these parameters.
-Making production versions in SAP according to line labor standards, no production can be done without the production versions in SAP which are combination of Bill of materials & Line Labor Standards.
-Driving CONTINUOUS IMPROVEMENT in the factory through Loss Analysis tools such as Loss Tree Analysis, IPA, etc and driving improvement through six sigma projects i.e. DMAIC and other improvement studies such as Activity Value Analysis to optimize labor, time motion studies, feasibility studies with cross functional teams etc.
-Evaluating the performance of all areas of the factory through the annual NESTLE SELF ASSESSMENT Tool and reporting to Zone i.e. Asia Oceana & Africa.
-KPI REPORTING to Zone & Technical Management & driving improvements against the KPIs.
-TRAIN factory employees on KPIs as per General Instructions guideline documents.
Team Leader Production & TPM circle facilitator at Wall's Ice Cream Factory.
-Production order planning, scheduling and execution for 100% plan delivery.
-Raw and packing material usage control for maximum output, minimum wastage and give away.
-Liaising with all stakeholder departments (Warehousing, Process, Distribution and Maintenance, Engineering) for material issuance, reparation of the mix for production and transfer to the cold stores, and necessary maintenance of the machines.
-Leading and implementing wastage reduction projects through operational and machine improvement projects/Kaizens.
-Design and implementation of machine layout improvement projects for a quicker and cost effective Operation.
-Maintenance of the plant during the shift.
-Downtime reduction through machine improvements and Staff training.
-Machine trailing and de-bottlenecking of new product and packaging developments.
-Ensuring and maintaining highest standards of quality, hygiene and consumer safety.
-Implementation of Quality improvement projects on the production floor.
-Implementation and ensuring OH&S standards for a zero injury environment.
-Leading and implementing TPM activities on the floor.
Designed both horizontal and vertical type pressure vessels with the help of the latest ASME Section VIII Boiler & Pressure Vessel Code. (In association with JGC-Descon).
Designed a heat exchanger according to the TEMA standard. (In association with JGC-Descon).
Learned the basics about the types and design of cone roof storage tanks at JGC-Descon.
Comprehensive study & troubleshooting of Pyroban fire safety system installed in fork lift trucks at AkzoNobel ( Formerly ICI Pakistan Limited, Polyester Fibers Plant.)
Awards / Accomplishments: -The second Asian recipient of The American Society of Mechanical Engineers (ASME) scholarship in the entire history of ASME. - Won the Technical Webpage Contest at the ASME Student Professional Development Conference (SPDC) held at BITS Pilani, GOA, India.(June 13th-14th, '10) - Won the Technical Webpage Contest (Wind Risk in Wind Turbines) at the ASME Student Professional Development Conference (SPDC) at Nanyang Technological University, Singapore.(May 16th-19th, '09) - Represented ASME members of Pakistan at the SPDC Singapore & also participated in the Product Design Workshop, Leadership Seminar and an industrial visit to Tiger Breweries. (May 16th-19th, '09). - Won ASME Student District Operating Board (SDOB) Vice Chair competition at NUST EME during the ASME Student Leadership Seminar after a series of presentations, a case study & voting and . (March, ‘09). - Lead a team of 25 volunteers to All Pakistan NGO’s Festival, a charity event organized by The Road Association to raise funds for the homeless children.(19th-21st Sep, 08). - Received ASME Asia & Pacific Leader’s medal for excellent management & dedication in organizing the Asia Pacific Student Professional Development Conference, April '08.