TPS-Kaizen Manager
Toyota -Abdul Latif Jameel Co.
Total years of experience :17 years, 11 Months
•Working as TPS-Kaizen Manager reporting to division Managing Director:
Core Responsibility: Facilitate accessories business by implement TBP Toyota business practice, focus on standardize operational procedures & kaizen activities.
• Responsible to maintain installation operation TPS in coherence with Toyota standard by ensuring continuous improvement of productivity, optimum utilization of resources (Manpower, tools & equipment) & proactive quality solutions.
Key Accountabilities:
o Responsible to organize, consistent & timely development of installation processes & installer trainings with desirable tact time for each model grade
o Responsible to monitor & control installation quality (Jidoka effectiveness)
o Responsible for directing all the activities of TPS-Kaizen section & increase capabilities of entire team by constant training & assign special projects.
• Responsible to facilitate continuous improvement (KAIZEN) activities & appropriate innovation of JACS manpower skills & operation condition.
Special projects (JACS Kaizen):
- Year 2017 Optimization of Warehouse operation
- Year 2016 Improve ordering (Revisiting JACS Ordering Module: Introduction of RPPS)
- Year 2015 Introduction of JACS Kaizen Marathon event
- Year 2014 Conduct first PIOC Internal Kaizen Marathon
- Year 3013 Implementation of JIT (just in time) vehicle flow for PIOC operation. : Lead TPS-Kaizen section to improve the effectiveness of the section for improvement TPS methodology in production
- Year 2012 Improve part flow operation for low tact time vehicles
- Year 2011 Introduction stage/station wise tools at TPS lines (2)New vehicles damage reduction
• Co-ordinate annual DB (Development Base) assessment/Audit with TMC-CAOD & all JACS departments & follow up action plans
• Co-ordinate all JACS departments to achieve division annual targets by developing HOSHIN at each department level. Follow-up manpower engagement surveys & impact planning
Working as Project Manager - Responsibility: Project Management, prepare & monitor the short & long term projects, enhance business activities explore new resources.
8-years experience in production planning, project management & material control operation.
- To ensure the availability of parts for smooth production.
- To resolve the inventory related matter in SAP.
- To ensure smooth running of production through (JIT) just in time supplies of parts (CKD & local parts) to weld, assembly line & paint shop.
- Inventory monitoring and storage according to FIFO (First in first out Technique)
- Parts modification correspondence to TTC-JAPAN, TMT- THAILAND, AND DMC-JAPAN.
- To implement the CKD and local parts modification on assembly line
- To facilitate the internal & external auditors during conduction of Audit & effectively utilization of man power: conducted two annual audits of CKD ware house and Multi-source parts (Parts receive from various countries other than Japan)
Project Management:
- Looking after planning, budget approval & erection of machineries (particularly material handling equipments)
- Prepared the budgetary cost of all proposed projects.
- Obtain project plan approval & conduct a kick off meeting with all key persons.
- Define and record detail project requirements, constraints and assumption with stakeholders to establish the project deliverables.
- Develop the change management plan to define how changes will be handled to manage the execution of project
- Manage proactively the resource allocation by ensuring that appropriate resources and tools are assigned to the tasks according to the project plan
- Execute the tasks defined in the project plan in order t achieve the project goals.
Reward Obtained:
First Prize (8th Kaizen i.e. Improvement suggestion convection/certificate)
Third Prize (9th Kaizen i.e. Improvement suggestion convection/certificate)
Special Prize (10th Kaizen i.e. improvement suggestion convention/ certificate)
Overseas Projects Working:
Worked on TSAM (South Africa), TKM (India) & IMC (Pakistan) plants, working on these projects given me an opportunity to gain knowledge in the field of project management & Supply Chain:
1-TSAM (Toyota South Africa Motors) SOUTH AFRICA:
Worked on TSAM plant as a support expert for system improvement & production support operation particularly:
-Import parts flow planning, warehouse layout & manpower estimation. Job balancing & preparation of unit work element time (Gentani), Yamazumi preparation training for managers Parts warehouse /Access warehouse (Type: Free Location warehouse). Making OP (operating procedure) through work element study of each process & feasibility check.
2- TKM (Toyota Kirloskar Motors) INDIA:
PMR- (Plant Management Requirement) implementation support in TKM-(Toyota Kirloskar Motor) mainly for logistics area:
-Step0, Step1 implementation phase support & Step2 start-up preparation. Developed more affective & enrich the skill evaluation sheet for step1 PMR examination.Determined Step1 result & signaled TKM internal logistics weak areas in entire part supply chain.
Trainings:
I got following trainings during ICT period in Global Production Centre GPC-Motomachi:
-Detail training of VM (Visual Manuals) of PLC (Production & Logistics Control)
-TPS Training from TPS group Motomachi plan.
-VM instructor training for New model parts & Runout activity.
-e-Kanban training
-Project Management / Project planning PPD & PLD working steps.
-Logistics Project scope & real operation
Final Comments:
During my stay in TMC I have considerably improved my skill & knowledge in field of Logistics & production control operations & I have acquired basic knowledge of management tools. After returned I rejoined IMC and promoted as Deputy Manager - Production Control.
1995 – 2000: Bachelor of Engineering (Mechanical) 1st Division – NED University Karachi – Pakistan 1992-1995 : Intermediate (Science) A grade – Board of Intermediate Karachi – Pakistan 1992 : Matriculation (Science) A grade – Board of Intermediate Karachi – Pakistan Contribution across many variants of the supply chain manufacture of large system, project handling, devaning, storage, unpacking, binning, picking, re packing & external logistics working (i.e. truck schedule, dock control, P-lane operation, PC store operation etc.), looking after production planning, budget approval & erection of machineries (hoists, air pressure guns, visual control electronic boards).
