Factory Manager
A. IFFCO EGYPT
Total years of experience :31 years, 7 Months
* Factory Manager (Laundry Soap): March 2013- To date
A. IFFCO EGYPT
* Factory Manager (Edible Oil): Sep 2011- Feb2013
• IFFCO Egypt certified standards: ISO9001-2008, HACCP Codex, ISO 22000, ISO17025 lab accreditation, BRC / Food ( version 5), McDonalds SQMS, ISO14001-2004 and OHSAS 18001-2007,
Yum FSA and QSA.
Responsibility as Technical Director
• To study feasibility of project, technical know-how, basic and detailed engineering of various bid of technology supplier, technology & cost comparisons, deciding scope of techno-commercial bid.
• To recommend for collaborator/technology supplier and approve with board of directors and C.E.O.
• To compare and decide various techno-commercial offers of various consultants for pre decided process, plant, equipment's and building.
• To Plan, schedule, coordinate, implement, monitor & follow-up of erection, pre commissioning and commissioning with collaborator, consultant and contractors for timely, quality and within budget completion of project.
• Reporting, Inspection & statutory requirements activities of various project works upcoming, ongoing & revamping.
• Training, advising, counseling local staff & expatriates and management for trial & commercial run.
• Operation, maintenance and management of plant, equipment and machineries for optimum output.
• Knowledge of international codes and standards.
Accomplishment (IFFCO EGYPT)
• Installation & Commissioning of Margarine Processing Plant (GS) of 7.5 MT/ HR Capacity
• Up Graded Margarine Processing plant (Schroder) from 4.5 MT/ hr to 7.5 MT/HR.
• Installation and commissioning of filling line for Pastry Margarine (2 kg- 10kg Blocks) and linking it with Margarine and Shortening Processing Units.
• Installation of Shortening filling line (EMEC) of 10 MT /HR capacity and connecting it with Margarine & Shortening processing unit.
• Installation & commissioning of Semi-Automatic Laundry soap Plant (Mazzoni) with Saponification plant capacity of 6Mt / HR and Finish line capacity of 3 MT/HR, with the provision for future finish line of same capacity. 2 No's of packing lines Flow pack ( Mazzoni), Carton Forming & Filling Machine (Zucchini) for Long and short bars, Complete civil work from ground level, Steel Structure, FGWH, Tank farm with unloading station (oil & chemicals) utilities (compressor, cooling tower, chiller, hot well, Fat traps etc.) High and low voltage electric substation, Transformer, Standby Generator, Loading Platform, Weigh Bridge, external roads, Drain lines, Boundary wall etc.
• Up grading of Refinery (Physical & chemical) to enhance the capacity by 12 % (From 400 to 450 MTD), Installation of CIP & Automatic change over system.
Accomplishment (IFFCO PAKISTAN)
• Involved in selection of Civil/mechanical consultant for the expansion project.
• Hydrogenation plant capacity 200 MT/Day for Ghee manufacturing
• Installation & commissioning of Hydrogenation plant capacity 200 MT/Day.
• Installation of Hydrogen Gas Generation Plant (Electrolyzer)
• Installation of Shortening/Margarine plant of capacity 5 MT/Hr
• Oil & ghee Filling plant (4 high speed lines)
• 4 Cold rooms of 100 MT each capacity
• Fabrication of various capacities of Carbon & Stainless steel tanks with steam Coils.
• Acquired permission from SSGC for captive power generation for 4 No's of generators & laying of 12" Dia &1900 meters long Pipeline up to our plant.
• Installation of 4 No's of 1000 KW Gas Generators with co-generation for producing steam (from waste heat recovery boiler through exhaust gases) & Hot water for jacket water heating)
• Enhancement of plant capacity from 800 MT/day to 1000/day by replacing
Various Pumps, Additional PHEs, modifying level controls, piping and re-commissioning of High pressure boiler etc.
• In 2007 called by ERCO & IFFCO EGYPT Management for technical advice to solve issues with HP Boiler, MS Deodorizer Capacity and Re- Commissioning of IFFCO Egypt QS Refinery after solving the issue of deodorizer, cooling tower and Amma filters.
* Technical Director: Jan 2006- Dec 2007
B. IFFCO PAKISTAN
* Factory Manager: Dec 1999 - Dec- 2005
C. Evian Fats & Oils (PVT) Ltd - Jan1996-Jan2006
• Responsible for production scheduling & inventory control, process control, Oil Losses, quality, etc. for an Edible oil refinery of 800 MT/day capacities.
• Receipt, storage & issuance of raw materials including transfer of crude oil from ship, bulk oil storage & deliveries.
• Responsible for Can/Bottle filling Plant (consumer packing)
• Corrective and preventive maintenance of all stationary &rotating equipment (high speed centrifuges, all types of pumps, motors, boilers, generators, compressors, cooling towers. steam ejectors, heat exchangers, valves, instruments, control panels, vessels, tanks etc.)
• Maintenance planning scheduling & execution, modification of plant where required.
• Inventory control of spare parts.
• Develops standard practice, job description & operational procedure, refinery internal specification & parameters for processing of various types of oils, preparation of management reports, trend charts etc.
• Costing of oil processed, steam produced & electricity generated.
• Prepares feasibility reports for expansion, modification &cost cutting projects involving capital expenditure & implementation of above projects.
• Responsible for preparing the annual budget for Capital expenditure & Spare parts requirement
• Negotiations with CBA/grievance handling.
Equipment Handled: Oil Processing Plants
• Physical refineries - 800, 600, 400 MTD (Desmet)
• Chemical refinery - 450 MTD (Westfalia Neutralization, Winterization-Desmet)
• Fractionation (Palm Oil) - 600MTD (LIPICO) 1V 56, 60&64 (Double fractionation)
• Hydrogenation Plant with post bleaching and MS deodorizer- 60 &90 MTD.
Oil & Fats Processing Plants
• Margarine/Butter Processing plant (2*7.5 MT/ Hr) Gestenberg Schroder (Now SPX Flow technology)
• Shortenings Processing Plant (13.5 MT/ Hr) Chemtech International.
• High Speed Filling lines for Margarine (Benhil & B&SONs) & shortenings (Pattyn & Emec) (154-120 & 280 &150 MTD Respectively)
• High Speed Oil and ghee lines (9 lines) From 76-180MTD.
• High speed 1 ltr Bottle blowing machines (7000-12000 BPH)
UTILITIES
• H2 Batteries- 100 & 280 NM3/ Hr.
• Low and High Pressure Boilers- 3*14 Bar & 3*86 Bar respectively.
• Air (9) -Ammonia (5) &Freon (26) Compressors (Screw and reciprocating type)
• High Pressure Air Compressors -3* 40 Bar
• Cooling Towers (17) Different types.
• Evaporators, Chillers. (Different types)
* Production Manager: July 1996 - Nov 1999
* Production Engineer: Jan 1996 - June 1996
Responsibility as Factory Manager
• As a Factory Manager responsible for Manufacturing cost, systems implementation, waste elimination, Head count, Factory Budgets (Utilities, gas electricity water), OEE Management, Employ Development & engagement, Production conformance, Factory works committee etc.
• Responsible for supply chain and manufacturing operations.
• Ownership of Procurement, Production/Material Planning, Production Control,
• Manufacturing, Process Engineering, Quality, Logistics and New Product Introduction function.
• Devise and drive the organization KPI's
Accomplishment
• Accomplished in supply chain, planning, production, quality, process/product engineering and new product introduction
• Taking products from concept to high-volume manufacturing
• Using ERP/BAAN throughout operations
• Maximizing operational agility to meet customer demand
• Built strong management teams, developed solid operating plans, and achieved results through employee empowerment
• Identifying and eliminating non-value added activities
• Streamlining workflows and creating a team environment
• Successfully completed business development, green fields, turn-arounds, capacity ramps, and consolidations while leading and motivating a workforce
• Meeting company's financial plans and KPIs
• Established new levels of leadership promoted lateral thinking and improved performance metrics within the company's core operating P&L disciplines.
• Established.
GMP & HACCP system.
OHSAS ISO18001-2007 and ISO14001-2004.
Environment and occupational health and safety management systems.
• Established quality management systems as per requirements of multinational customers as Mac Donald SQMS, Yum, Kraft, Burger King, PepsiCo, Nestle, Unilever, GSF, Carrefour and got their approval for IFFCO Egypt site as an approved supplier
D. GENERAL TYRE & RUBBER COMPANY OF PAKISTAN ( PVT) LTD
1985-1995 (10 Years)
• SR PRODUCTION EXECUTIVE
• AREA MANAGER
• MANUFACTURING ENGINEER
• TRAINEE ENGINEER
• Responsible for production, production efficiencies, productivity, quality of product & equipment maintenance.
• Managed 60 Workers, 5 Supervisors, 1 Engineer
• Maintain key quality indicators (waste scrap), monitor quality assurance program like SPC, Traceability, etc.
• Planned monthly production schedule and daily follow up on schedule.
• Developed standard practices & management reports, plan preventive maintenance program in coordination with maintenance manager.
• Suggest modification in existing machinery.
• Monitor ongoing projects in the area and cross training programs of workers &supervisors.
E. PAKISTAN ARMY: CAPTAIN EME Corps 1982-1984
• Apart from other military duties, was responsible for scheduling of repair/maintenance program on monthly/quarterly & annual basis, Base overhauling of Diesel & Petrol Engine, heavy mechanical equipment like Armored Vehicles, Earth moving equipment's like Dozers, Wheel loaders, Cranes, Compressors etc. Phasing and Calibration of fuel injection pumps on Hartridge & Merlin test bench.
• EME College Quetta Young officers Eng. Short course. 3. Business Institute of Pakistan Air Force- 2000-2001 • Courses in Marketing and Finance (10 Courses) PROFESSIONAL AFFILIATON: • Member of Pakistan Engineering Council (Reg No. Mech/4357)
• B.E. (Mechanical) 1st Division from N.E.D University of Engineering & Technology, Karachi Pakistan in 1981.
Karachi University • BSc (Physics, Chemistry, Math's) 1st Division- 1975 SPECIAL COURSES : Ohio State University 1. USA • At OHIO State University in the Department of Industrial & Systems engineering (ISE), through USAID Scholarship program (6 months) In 1991. 1. Production/Operations management, 2. System's dynamics, 3. Material handling system, 4. Industrial plant design, 5. Robotics in (ISE) Industrial and systems Engineering 6. Computer method Engineering, 7. Inventory & manufacturing control. 2. Pakistan Army