Execution & Maintenance Manager
Allied Bank Limited
Total years of experience :19 years, 6 Months
Key Responsibilities & Achievements
As an execution and maintenance manager lead Rs.600 Million project involving Execution, Testing and Commissioning of Central HVAC System, Lifts, Gensets and other services for the new Head Office facility.
Direct all aspects of Execution, Testing and Commissioning. Establish performance indicators, operating goals, productivity improvements, and cost reduction programs that consistently improve product output and quality.
Evaluate work performed by contractors, sub-contractors, and equipment vendors to ensure execution in accordance with project specifications and regulatory requirements.
Develop and lead maintenance team based on Total Productive Maintenance (TPM) and Reliability Centered Maintenance (RCM) techniques. Manage maintenance performance along with metrics to manage preventative maintenance, cost performance and equipment analysis.
Ownership for site parts inventories, parts management and technical relationships with vendors. Place orders to the vendors and make payments after verifying the functioning of the materials and equipment.
Developed commissioning plans, reports and functional test procedures. Coordinated with equipment suppliers to test new installations & mechanical systems and troubleshooting any error during commissioning to strategically deliver project 8 months before deadline.
Deployed organization development plan to support flexible work force to reduce idle time from 30% to 15%. Provided leadership to direct report employees along with facilitating career development, performance goals and feedback discussions.
Led and Trained in the use of TPM based CI improvement tools including a wide range of Early Management tools, FMEA and Root Cause Analysis. Prepared schedules for repair, overhauling, and maintenance of all equipment and machinery.
Key Responsibilities & Achievements
Remained accountable for lean process improvements, financial performance, contractor relations and coaching project teams to affect process change and achieve bottom-line results in sixty days or less.
Using the 3R methodology, reduced the water ratio by 60%, increased water bottling capacity from 13000 to 20000 per day and reduced RO rejects by 25%.
Led Rs. 30 million capital improvement project involving up gradation and replacement of construction machinery resulting in maintenance cost savings of Rs. 3 Million per year.
Completed the acquisition and installation of Rs. 3 million pipe manufacturing facility which improved production capacity of major products by 35% and reducing labour cost by 40% over one year period.
Created project tracking and updating system to assist management in receiving project status reports and manage the multi-project landscape and resource capacity issues.
Secured bottom-line savings of Rs. 1.5 Million and 10% headcount reduction by implementation of 5S, flow manufacturing and instituting production controls including Kanban and Control Boards.
Streamlined back office by applying Lean Six Sigma and value stream mapping (VSM) to core processes in Sales, Finance and Procurement that saved Rs. 2 Million per year.
Developed and stream lined new supply chain for construction raw material based on local initiative and reduced inventory by Rs. 2 Million.
Key Responsibilities & Achievements
As a black belt, led lean six sigma projects from proposal to completion. Liaised with cross functional teams in projects selection, setting improvement targets, reporting and performance measurement.
Led project teams to re-engineer business processes, develop IDEF diagrams using IGrafx, select and implement Enterprise Resource Planning system according to specified business control model.
Trained staff to introduce advanced Lean tools and techniques including 5S, Total Productive Maintenance (TPM) and Just-in-Time (JIT) to increase throughput and plant productivity.
Conducted time and motion study on shop floor to reduce production lead-time of hob cutting by 30%.
Established production method to transfer manual polishing of material to polishing on NC Machine to improve production flexibility and reduce the cost of polishing by 32%.
Analyzed and automated the surveying operation using digital equipment to save £50, 000 per year.
Re-engineered the quotation process and improved the excel based costing programme for quotations to reduce the number of documents from 24 to 8 and saved order processing time and cost by 15%.
Analyzed the company’s current spending on telecommunication and phones and proposed the new mobile phone contracts to bring cost savings of £7000 per year.
Analyzed the company’s spending on travel and automobiles and suggested to consider vehicle hire to reduce the cost of logistics operation by £35000 per year.
Modified and standardized operating procedures in operations and accounts to save £80, 000 per year.
Key Responsibilities & Achievements
As a programme leader, led execution of projects from proposal to completion. Liaised with cross functional teams in projects selection, setting targets, reporting and performance measurement.
Managed programme budget of Rs.30 Million for commercial and domestic construction development.
As an operation manager worked with suppliers and subcontractors to schedule materials supply, installation of pipes and wires for gas and electric supply to reduce operational cost by Rs. 0.5 Million.
Assisted cross functional team in operations to negotiate purchasing of transformers and industrial machines for sites development to reduce project cost by Rs.3 Million.
Key Responsibilities & Achievements
Assigned project planning, scheduling and role allocation task for client’s project in Pakistan.
Examined reasons of failure of heat recovery unit using HAZOP study. Led a project team to redesign and propose heat recovery duct for 25MW gas turbine using Solidedge and AutoCAD.
Assisted in Thermal and Fluid flow analysis using Ansys & Cosmos to validate design stability. The structural and fluid flow analysis of duct saved £30, 000 for the company.
Gained hands on experience on MS Project and exposure to the dynamics of a professional organisation.
OBH TECHNOLOGIES
Key Responsibilities & Achievements
As project engineer remain involved in planning, team selection, coordination and commitment throughout the project lifecycle.
Led a project team to specify new loom & winder design to improve throughput and plant productivity.
Redesigned the shop floor layout and production flow to reduce production lead-time by 15%.
Dealt with suppliers and subcontractors to resolve issues in production and quality control.
Attended workshop on KAIZEN basics including the implementation of two-bin Kanban System.
It is a Vocational Course in Management at NVQ Level 4. Based on the evidence from different activities at work each module will be awarded and a Chartered Manager status at the end of course.
Pass (Non-Gradable) Courses Studied: Logistics and operations management, Operation strategy for industry, Product design and development management, Strategic marketing, Quality control, Project planning management and control, Financial Analysis and Control Systems, Supply chain management and Enterprise information systems. Thesis: To investigate compatibility issues in Lean Manufacturing and ERP System in a fast moving environment concentrating at production planning and Control. - Investigated modern practices in lean manufacturing and ERP systems. - Identified compatibility issues in the area of production management and control concentrating at production at control. - Proposed solutions to issues to enable ERP push meet Lean Pull.
- 1st Distinction - Recieved Rs 5000 scholarship for achieving 3rd position during 2nd year of mechanical engineering. - Successfully completed internship with Descon Engineering Pvt. Ltd. COLLABORATIVE AND ACADEMIC PROJECTS - Packages Limited, Pakistan: A technical study on “Efficiency improvement of steam power plant” and calculation of payback period. - Masters Textiles, Pakistan: Technical report on “investigation of failure of heat recovery unit and redesign and analysis of inlet duct to heat recovery steam generator”. - U. E. T. Lahore: Feasibility report on “Installation of steam and gas turbine power plant” at Lahore campus. - Manufacturing Processes: Technical report on “Study of manufacturing processes for Pakistan Railways”. - Energy Resources & Utilization: Design and Fabrication of wind turbine for the mechanical department.
Mathematics A* Physics A Chemistry A