Sr Team Manager Inventory Planning
Almarai Company-Alkharj Saudi Arabia Dairy, Juice, Cheese Plant
Total years of experience :13 years, 8 Months
• Determine materials demand and align supply schedules with the help of SAP IBP (integrated business planning) and align overall supply chain operations to company objectives,
• Create manual MRP on excel to keep a check on materials demand figures are showing exactly accurate in SAP planned orders,
• Monitor and activate system generated or manually generated purchase requisitions,
• Help launch new products by determining materials demand as per products launch timelines and volumes,
• Review master data for accuracy of information and align the necessary changes where required,
• Review working capital, forecast of 82 weeks, stock levels, and take corrective actions and optimize safety stocks keeping service levels in consideration,
• Generate within SAP weekly & monthly schedule agreements call off with all the local and GCC suppliers,
• Liaise with Production planners daily to ensure that the deliveries of externally supplied Glass Jars meet the next 24-hour filling plan,
• Assess materials supply planning schedules seeing coverage profiles, create report for rescheduling where deliveries required to delay or advance,
• Prepare monthly performance report of supply chain department, highlighting top/worst five suppliers, materials values/covers, obsolete or slow-moving materials,
• Prepare report highlighting materials getting critical along with issues and actions taken for timely resolution,
• Prepare a comparative report of finished products forecast, planned orders and actual production volume variances,
• Cover for Seniors during holidays or sick leaves and deputize the junior team members as and when necessary,
• Generation of material & ingredients run out plans to minimize obsolete stocks, manage artwork changeovers and manage a smooth phase in and phase out process.
• To manage master production schedule (MPS) of 800+ Finished SKU’s of two manufacturing plants for local, international and institutional demand and sale order,
• To determine finished products demand as per sales forecast and safety stocks to ensure get all products at right time and in right quantities,
• To translate MPS into daily production schedules and to manage materials dispensing plans as per production schedule,
• To review forecast seeing secondary sales, highlights any overrated or underrated figures, and validates forecast for discussion with sales and marketing teams,
• To help improve MPS, capacity planning, supply planning and MRP process flow and keep automating and simplifying processes,
• To manage materials supply quantities and delivery timelines based upon agreed lead times and required quantities,
• To attend daily and weekly meetings and share updates on products or materials status. Also highlight challenges related to supplies sensitive areas and conduct root cause analysis for supply chain issues to avoid any repetition,
• To convert budgets into yearly capacity and materials requirement plan and advise on excess/short capacity process wise,
• To execute toll products manufacturing plans and ensure final product are delivered to customers at right time and quantities,
• To manage team work load and distribute tasks of Planning Section and other urgent tasks and duties per available skills of the team,
• To keep a record of obsolete materials/products at plant or distributor and make plan for consumption or write off.
• To monitor inventory and take actions to ensure their optimal level according to stock keeping policy.
to plan in-house production of 160+ sku's and their respective materials procurement Inventory levels and procurement planning to ensure inventory controls limits are adhered,
to plan supplies of imported finished goods, maintaining 3 months demand cover, share forecast and actual sales trends, and raising PR's and following up until deliveries reach at site.
to schedule manufacturing and packing of batches per inventories availabilities, sales requirements and plant capacities,
to plan and streamline contract or toll manufacturing of finished products, determining materials required for toll manufacturing, and managing smooth transactions of materials and finished goods,
to plan phase in and out of new artwork of packing materials and ensuring less write off to launch in time revisions,
to monitor plant capacities, advise any changes required for long term forecast achelievement, and ensure plant capacities are utilized to maximum limit,
to review and guide S&OP data preparation, highlight issues related to forecast inaccuracies and demand and supply issues,
to upload MPS into SAP and run MRP,
to communicate daily routine issues to production, marketing, quality and other stakeholders.
• To lead supply chain by aligning to the organizational goals, helping juniors to understand and perform accordingly.
• To lead S&OP to streamline sales, production and supply chain priorities.
• To plan capacity, production and materials at the beginning of every period. Giving subordinates clear instructions for procurement, production control and materials issuance.
• To discuss with suppliers about new products requirements and developing new sources after getting samples approved.
• To develop new cost effective sources which can provide committed flow of inputs.
• To lead materials issuance, storage, stacking and dispatch to make it flawless.
• To guide dispatch teams on priorities and urgencies.
• To help develop and maintain ERP relevant to the work processes of supply chain.
• To coach team in order to enable them to keep performing under high work pressure.
• To approve PR issued by all departments and supply chain officers and executives.
• To lower cost of goods sold as a percentage of sale in order to improve overall supply chain effectiveness.
• To align supply plans (MRP, delivery schedules, order quantities) with demand plans (MPS, SARAS, Forecast) keeping lead time, MOQ, other supply chain sustainability considerations in mind.
• To liaise with buyers and central procurement to manage any supply issues, and deal with any impact on material requirement plans.
• Maintain the portfolio Working Capital within budget levels by maintaining optimal stocks of all items through detailed planning and review.
• Scheduling of deliveries from suppliers based in GCC, must consider any space constraints within warehousing operations.
• To ensure 100% optimization of the Poultry Processing Plant. Maintain desired stock levels at co packer’s plant.
• Generation of ingredients & packaging materials run out plans to minimize obsolete stocks.
• To liaise with buyer, product development manager, materials master analyst and SAP support team to ensure correct initiation of new item specifying other measure like description, plant/storage locations, cost center, artwork references etc.
• Responsible to make yearly stock purchase plan, align on monthly and weekly basis to ensure optimal levels.
• To manage work load and distribution of Planning Section and other ADHOC tasks related to supply chain duties & functions.
• To review the weekly Production plans with the Central Planning, MRP Controller and the Manufacturing management.
• To monitor and activate system generated or manually generated purchase requisitions, expedite PO at CPD and monitor PO acknowledgement and deliveries by suppliers.
• To review master data for accuracy of information, and inform material master analyst for the necessary changes where appropriate.
• To provide information to operations, production planning and MRP Controller on supply or supplier related issues.
• To create purchase and release requisitions within SAP in order to maintain agreed packaging materials & ingredients stock levels.
• To generate within SAP weekly and monthly schedule agreements with the entire local and foreign supply base.
• To liaise with Warehouse department to ensure that no outstanding GRN’s exist within the portfolio, identify and resolve receipt differences with finance, stores and suppliers.
• To liaise with Production Planners on daily basis to ensure that the deliveries of externally supplied pre-labeled packages meet the next 24 hours production plan.
• To plan and/or execute inventory goals by product/supplier and plan/develop systems to take decisions to meet materials control objectives (i.e., JIT, Pareto principles.)
• To interpret systems output and framework to determine items requiring follow ups from suppliers to ensure on time delivery. Run MPS and MRP in order to determine finished goods and raw materials status and requirement.
• To manage demand by developing demand plan and aligning supply plan for finished products as per sale forecast.
• To schedule materials for 5 manufacturing plants (3 in Karachi, 1 Lahore, 1 Islamabad) based on MRP and expedite deliveries that are to be used in production run or are delinquent or expected to be so. Ensure optimum or required capacity is being utilized to mitigate any shortcoming.
• To evaluate sale forecast trend and production capacity according to working days available before its finalization in to MPS and MRP. An active team member for NPD.
• To act as primary communication link between tactical and strategic supply chain functions and business units; participates in supply chain team activities and prepare planning reports from the system (ERP).
• To plan import supplies and manage their current pipeline stock status to manage production planning properly and to maintain optimum stock level and get supplier confirmation for delivery dates and timelines.
• To arrange L/C, Bank contract and telegraphic transfers and taking release of shipment from customs by providing required documents to clearing agent.
• To select suppliers, shortlist them, evaluate them, and then place orders accordingly. Manage supply according to firm needs and supplier capabilities keeping price, quality and delivery needs in consideration.
• To initiate negotiation, estimate product price and compare all relevant points of quotation in context of supplier capability, product inputs and our requirement. Keep sustainable business considerations in to supply plans decision making.
• To monitor inventory as a current asset and take actions to ensure their optimal level according to stock keeping policy. And get supplier confirmation for delivery dates and timelines.
• To keep a record of obsolete materials at supplier/factory plant and make plan for consumption or write off.
To develop and implement departmental Standard Operating Procedure (SOP’s) and Work Instruction (WI’s).
• To implement QMS, EMS, OH & Safety system within the department.
• To ensure all working persons in the department are properly trained.
• To prepare production plan for current month based on sales forecast and for next two months.
• To recommend and implement improvements in plant and process activities for increasing efficiency.
• To monitor all activities of Production Planning & Control Department in the factory.
• To maintain an updated record of plant capability/capacity. And to generate manufacturing work orders and implement Monthly Production Schedule based upon Production Plan and available material inventory.
• To perform and record time study of all production departments and prepare and finalize product wise Bill of Materials.
• Monitoring daily Production against agreed targets and prepare for reviewing daily production and efficiency reports.
• To ensure smooth running of Material Issuance Software “SCM”.
• To ensure compliance of OH&S practices within department and Supply Chain Department complies with company policies and procedures, practices and systems, and maintain high standard of work and work ethics with other departments and colleagues.
• To create PR (purchase requisition) and keep follow up of PR with purchasing and import departments.
• To attend monthly meetings regarding product performance based upon Internal and Market/Sales feedback.
• To sanction leaves of subordinates and appraise and forward the performance of subordinates.
• To recommend and approve subordinates gate pass and create new materials code and new products BOM.
• To provide direction, prioritize tasks and activities, assign and delegate responsibilities and monitor the workflow of the Supply Chain Department.
• To prepare master production schedules (MPS) and materials requirement planning (MRP) on ERP and excel to control production and demand for the market.
• To analyze inventories to determine how to increase inventory turns, reduce waste, and maximize internal customer service.
• To expedite materials from suppliers and indenters by keeping in close communication with production and suppliers. Plan demand for finished products by evaluating sales trends and forecast determining capacity to be utilized.
• To plan supply as per production schedule seeing warehouse space and requirement as per production run.
• To maintain 3 months finished goods in plant FG department and branch collectively to ensure flawless sales to avoid any stock outs. And to keep close follow up with procurement personnel and suppliers to ensure on time delivery of items and supply.
• To open LC, bank contracts, and telegraphic transfers for importing materials. Getting materials released from ADC and customs by following their procedure.
• To negotiate rates with indenters and suppliers for import supplies by finalizing incoterms for shipments.
• To insure imported materials. Cross checking the materials insurance manuals received from the insurance company.
• To discuss with clearing agents for timely release of imported items in order to avoid any extra charges. Getting issued drug import license from the concerned authorities when they got expired.
• To maintain LC, bank contract and TT status sheets with the figures of payments and relevant information to have an updated overview at any point in time
• To ensure Supply Chain Department complies with company policies and procedures, practices and systems, and maintain high standard of work and work ethics with other departments and colleagues.
• To plan raw /packaging material requirements for current and for next 3 months based upon sales forecast with MRP (deployment in MPS and then in MRP) on ERP (Oracle) and Excel keeping capacity in consideration and control inventory and production to avoid any shortages and overages. To run MRP/MPS and develop ERP based materials requirement.
• To weekly prepare a complete Production Schedule along with Production department for daily issuance of material and fulfilling market demand which is followed in the Warehouse and sales department before execution of shop and sales orders.
• To keep close follow up with procurement department for the timely deliveries of material in order to ensure flawless Production. Expedite the inventory on both sides from production and suppliers.
• To plan rough cut capacity and to plan product mix for meeting local and foreign market demand.
• An active team member of ISO inspection auditor team and of HSE inspection. To conduct monthly inspection of HSE and identify, evaluate and assess risk severity and probability of occurrence.
• To determine in process inventory at the end of each month for manufacturing and packaging of drugs.
• To keep close follow up with QA and QC departments for maintaining smooth and timely supply of raw and packing materials.
• To prepare a monthly Proposed Summary of drugs produced and packed in quantity and amount which is basically prepared in weekly breakups in order to give marketing and sales department an insight how Supply Chain would meet demand needs laid down in monthly sales forecast so that marketing and sales department can arrange their activities accordingly.
• To prepare an Actual Summary against the Proposed Summary that takes into account deliveries of drugs in to Finished Goods Department in quantity and amount which is also basically prepared in weekly breakups for drugs to be dispatched promptly and gives an overview of the objectives achieved.
• Issuance of materials by shop orders to the production department from warehouse for manufacturing and packing.
CSCP-Certified Supply Chain Professional APICS - Association for operations Management-USA Fundamentals of Supply Chain Management, Supply Chain Strategy, Design, and Compliance, & Implementation and Operations
I studied contemporary issues of modern supply chain management practices. I came across with the challenge of supply chain professionals for taking decisions on quantity to be ordered and determination of delivery/shipment time of supplies. This led me to select my research topic " A Pragmatic Study of the Factors Affecting Direct Materials Procurement Decisions". This study is based on the relative explanatory power of independent variables that impact on the decisions of order quantity and delivery/shipment time of supplies in order to have a rationale for these decisions.