Application and Technical Support Manager
Tate & Lyle
Total years of experience :22 years, 5 Months
Responsible for Pakistan and Iran
Key Areas of Responsibilities:
A. New Product Development (NPD)
B. Value optimization (VO)
C. Reformulation
D. Exiting Product Improvements (EPI)
E. Alternative Supplier Development (ASD)
F. Technical Studies/Support.
G. Process validation & optimization (PVO)
Responsibilities:
i. Independently plans, manages, and completes NPD/VO/EPI/ASD/PVO to design, develop, and optimize products with necessary shelf-life and sensory characteristics within designated time frame.
ii. To manage product/process/ingredient related compliance issues with the help of compliance department.
iii. Coordinating and conducting
a. Bench trials.
b. Pilot plant trials
c. Plant trials
d. Projects through external strategic partners when & where required.
e. Process finalization in coordination with project & process enablers.
f. Full scale manufacturing
g. Internal sensory evaluation using triangle, duo-trio & preference tests
h. Consumer Preference Tests (CPT)
i. Shelf life validation
j. Logistic transit trials.
iv. To develop final product approval (FPA) for marketing for label development, Product specifications for quality and comprehensive guides (GTP) for productions and to update all documents in Q-Pulse (document management system).
v. To involve in installation and commissioning of new equipment and machines, to conduct trial run during commissioning for product safety/standard and to approve to use the new machine or equipment for commercial production.
vi. To communicate project status to all concerns (including team members) by updating the development and validation activities in Accolade.
vii. Value Optimization: To identified the new opportunities to save product ingredient/processing cost, to deliver the budgeted approved value optimization project within the given time frame.
viii. Technical studies/support: to provide support in application of scientific methods and statistical tools, to provide expertise to in various areas ( food chemistry, food processing, ingredient functionality), to support departments (production, quality, procurement, logistic and sales) to solve problems in a timely and efficient manner, to conduct technical studies in coordination with external agencies.
ix. Alternative Supplier Development: To share with them the project brief, to evaluate their samples/solution on bench/pilot /plant trials,
x. Product specification/Processing steps/ parameters/storage condition/end of shelf life status finalization for new and existing dairy products.
xi. Process validation & optimization (PVO): to study the process details and to identify/validate new processing requirements for new product or reformulated product.
Almarai has AIM (Almarai Innovation Management) system, based on Stage Gate Process and supported by Accolade (Project Management System). Almarai uses Q-Pulse software for documents management. Product Developers uses Hamilton Grant software to develop the recipe and their nutritional facts.
Key Areas of Responsibilities:
A. New Product Development (NPD)
B. Value optimization (VO)
C. Reformulation
D. Exiting Product Improvements (EPI)
E. Alternative Supplier Development (ASD)
F. Technical Studies/Support.
G. Process validation & optimization (PVO)
Responsibilities:
i. Independently plans, manages, and completes NPD/VO/EPI/ASD/PVO to design, develop, and optimize products with necessary shelf-life and sensory characteristics within designated time frame.
ii. To manage product/process/ingredient related compliance issues with the help of compliance department.
iii. Coordinating and conducting
a. Bench trials.
b. Pilot plant trials
c. Plant trials
d. Projects through external strategic partners when & where required.
e. Process finalization in coordination with project & process enablers.
f. Full scale manufacturing
g. Internal sensory evaluation using triangle, duo-trio & preference tests
h. Consumer Preference Tests (CPT)
i. Shelf life validation
j. Logistic transit trials.
iv. To develop final product approval (FPA) for marketing for label development, Product specifications for quality and comprehensive guides (GTP) for productions and to update all documents in Q-Pulse (document management system).
v. To involve in installation and commissioning of new equipment and machines, to conduct trial run during commissioning for product safety/standard and to approve to use the new machine or equipment for commercial production.
vi. To communicate project status to all concerns (including team members) by updating the development and validation activities in Accolade.
vii. Value Optimization: To identified the new opportunities to save product ingredient/processing cost, to deliver the budgeted approved value optimization project within the given time frame.
viii. Technical studies/support: to provide support in application of scientific methods and statistical tools, to provide expertise to in various areas ( food chemistry, food processing, ingredient functionality), to support departments (production, quality, procurement, logistic and sales) to solve problems in a timely and efficient manner, to conduct technical studies in coordination with external agencies.
ix. Alternative Supplier Development: To share with them the project brief, to evaluate their samples/solution on bench/pilot /plant trials,
x. Product specification/Processing steps/ parameters/storage condition/end of shelf life status finalization for new and existing dairy products.
xi. Process validation & optimization (PVO): to study the process details and to identify/validate new processing requirements for new product or reformulated product.
·Motivating the staff by encouraging and empowering them.
·Maintaining good relations with all related departments.
·Overall management and control of quality and Product Development Budget.
·Updating of existing and development of new raw/packaging material Specifications.
·Quality clearance to all incoming materials.
·Follow up of non-conformance with suppliers and procurement department.
·Auditing of raw/packaging materials suppliers.
·Updating of ingredient list and nutritional information as per the changes in recipe and as per the applicable standards.
·Determining of specifications of all in-processing final materials/final products.
·Ensuring proper disposal/rework of all kind of in-processing/Final, non-conforming materials..
·Market visits
·Receiving, reviewing and recording of non-conformances (NC)
·Ensuring proper root- cause analysis of NCs and then accordingly implementing or advising concern staff for corrective and preventive action/s.
·Continuous Development/improvement/implementation/Monitoring of ISO 9001:2008 & ISO 22000:2005.
·As MR of ISO 90001:2008, & FSTL of ISO 22000 controlling all kinds of system related activities.
·Training of staff on ISO 9001, ISO 22000, GLP and GMPs.
·Improvement in existing products standards/recipes.
·Liaison with sales & marketing department for their requirements for new products.
·Ensuring monthly analysis of all types of competitor’s product available. ·Liaison of new raw materials suppliers.
·Liaison with plant for conducting plant scale trials.
·Developing and training of sensory evaluation panel.
·Reporting and recording all stages of product development/ improvements.
·Ensuring proper calibration of lab and plant equipments.
·Ensuring that all aspects of manufacturing are as per updated applicable standards (like GSO).
·Liaison with certification bodies, Pest controlling bodies, equipment/chemical suppliers, material suppliers, Local authorities.
· Motivating staff.
· Maintaining of good relations with all related departments.
· Developing SOPs for various activities and analysis.
· Training regarding Raw material related quality, GMPs, GLPs, and Hygiene at division level.
· Overall management and control of quality and safety budget.
· Implementation of ISO 9001 & ISO 22000 SOP at milk collection centers through the country.
· Coordinating and consulting within Company, Head-office, external parties and government authorities on safety, quality and regulatory matters.
· Training and coaching of field Quality/ procurement Staff.
· Liaison with the third parties to conduct the team building exercise at division level (Procurement).
· Receiving, reviewing and recording of non-conformances (NC) raised by production department.
· Taking full ownership of all customer complaints, ensure timely analysis, corrective action, customer response, and mistake proofing until affective resolution and full closure.
· Auditing of suppliers for Hygiene and GMP..
· Designing and implementing quality assurance training programs to key personnel of suppliers.
· Providing support to suppliers to improve their system as per ISO 9001 (Where applicable)
· Ensuring proper calibration for field raw milk reception labs/collection centers equipments.
· Ensuring of Proper standardization of all related chemicals used for raw milk testing.
· Ensuring Proper Hygiene for all field raw milk reception labs/Collection centers.
· Giving feed back to company SHE manager to formulate & maintain SHE objectives for Procurement Division.
· Maintaining/assuring that the company SHE-Manual is properly implemented at divisional level.
· Responding to Company SHE manager for planning, budgeting and training for SHE at Divisional level.
· Collecting and reporting all type of divisional SHE related data to management on monthly basis.
· Timely execution of all orders of top management.
· Overall management and control of quality and Research & Development Budget
· Maintaining good and healthy relationship with all concern departments.
· Motivating the staff by encouraging and empowering them.
· Taking part in regulatory affairs related with raw milk and various dairy processing on Pakistan Dairy Association (PDA) plat form.
· Updating (existing materials) and development (new materials) of specifications for raw/ packaging materials/ in-processing materials and final products.
· Auditing of raw and packaging materials suppliers.
· Ensuring in time analysis for all type of raw materials/in processing materials and final products.
· Sensory evaluation of all types of product before their release to market.
· Visiting markets throughout the country to train the sales staff as per observation of visit.
· Handling Non-Conformance, till it close down.
· Ensuring proper Calibration of lab and plant equipments.
· Ensuring proper maintenance of plant hygiene.
· Continuous Development/improvement/implementation/Monitoring of ISO 9001:2000.
· Development/Implementation/certification/monitoring of ISO 22000:2005.
· As MR of ISO 90001 and FSLT of HACCP, controlling all kinds of system related activities, including NCR and management review meeting follow-up, internal auditing, external auditing, trainings and liaison with other departments and etc.
· Training of staff on ISO 9001 HACCP, GLP and GMPs.
· Liaison with third parties regarding rodent and pest control, system audits and handling market complaints.
· New product development (Dairy and Juices and sweets)
· Improvement in existing products recipes/standards.
· Developing and implementing new raw milk adulteration tests.
· Liaison with plant/s for conducting plant scale trials.
· Reporting and recording all stages of product development/ improvements.
· Training of sensory panels.
General:
· Report writing.
· Communicating.
· Acting as a bride between Quality control of plant and Milk procurement.
Trainings:
· Trainings to Field raw milk procurement staff regarding Quality of raw milk.
· Conducting collaborative testing sessions for lab staff at company level.
· Trainings of GMP, HACCP, ISO-9001: 2000, ISO 14001:1996 and GLP, Housekeeping to Production, quality and raw milk procurement staff.
System related Activities:
· Monitoring and documenting HACCP related activities as a team coordinator.
· Coordinating with ISO 9001 & ISO 14001 team coordinator.
· Auditing of GMP, HACCP, ISO-9001: 2000, ISO 14001:1996 and GLP as an internal auditor and Lead auditor.
· Follow up of Non-conformance related with HACCP, GLP, Hygiene and GMPs.
· Follow-up of liaison with certification bodies.
· Implementing Rodent and Pest Control activities at plant level.
Lab Management related:
· Coordinating the activities of ISO17025 as a team coordinator.
· Preparing and standardizing of various types of reagents used in various lab at company level..
· Calibrating all equipments and glassware in various labs at company level and updating the calibration record.
Others Activities:
· Developing new test method especially for any new adulteration in raw milk.
· Preparing various types of reports.
· Coordinating the process improvement activities like loss monitoring, change of process and process parameters.
· Liaison with educational and research institutions.
· Taking part in regulatory affairs related with raw milk and various dairy processing on the plate form of Pakistan Dairy Association (PDA).
Managing Production activities on dextrose (powder) based product lines.
Controlling of loss at various levels.
Maintenance of ISO 9001 system.
To study about the Halal Food as per Islamic sharia. the shria rules for halalness of foods. How to proceed for Halal certification, what are the basic requirments for Halal certification, the firms involve in halal certifications.....
Its a customized course on the request of Engro Foods Limited. with Different Modules
This is M.Phil level regular program for one & half year, from one of Pakistan's best university. Last sex months are fully dedicated for research and thesis. My topic of research was " Development of Supplier for one of the leading food manufacturing company (Haleeb Foods)." I am Merit holder (among top ten students) in university securing 87% marks.
This is 2 years master's degree program (equilent to M.Phil). This degree program include last full year for research and thesis. I completed my research & thesis in Ready to Drink Soy-cow Milk Blend Preparation. My research paper was published in Pakistan Journal of Nutrition 6 (3): 283-285, 2007 with the title " Physico-chemical and Sensory Evaluation of Ready to Drink Soy-cow Milk Blend". I stood second in Food Science & Technology department, securing 87% marks.
This is 4 years degree program after 12th grade (Pre-Medical) from college. This degree program include all food science and thecnology related course with 3 months proactical training in last semester in any of food indutry. I stood second in Food Science & Technology department, securing 80% marks.