Manufacturing Engineer
Johnson controls
Total years of experience :12 years, 10 Months
Managing a pool of around 200 employees of different grades, Co-coordinators, Supervisors, Skilled and Unskilled
Labor.
Leading and training teams of with different levels of staff to increase their Multitasking skill and standardized
work as per Johnson control manufacturing system standard.
Leading Champion and Six Sigma practitioner of Continuous improvement & value stream flow, in order to
reduce cost, time, and work in process inventory flow & cultures behaviors to maximize productivity as per
standardized manufacturing system.
Managing overall sheet metal manufacturing process for manufacturing HVAC Parts like, Diffusers, linear
Diffusers, Dampers, Linear bar Grille and Assembly area of all Products.
Managing In-house fabrication (Lathe Operations, Welding, Cutting, Shearing & Milling) for developing new parts
according to Drawing and implementing method to generate ECR (Engineering change request) and ECR
(Engineering Change Request) for developing new Sheet metal Product.
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Working to improve on Product/process by using different Process improvement tools, Like DFM (Design for
manufacturing), Line Balancing, Value Stream Flow and other Manufacturing methodology in assembly line area
to minimize cost.
Responsible to Daily and Monthly Production KPIs are achieved 100% with assurance of on time Delivery to the
customer as per lead time within Allocated Resources.
Responsible of Production Planning & Execution at maximum efficiency, within Quality standards as per ISO 9001
and maintain high productivity.
Coordinate with Engineering and testing department for reliable testing of new product and its Quality
standards.
Working on Process improvement activities in sheet metal to improve productivity, reduce rework, Scrap and
improve quality of product
Evaluating complains data to improve product quality with respect to the process & specifications of refrigeration Standards & operating procedures.
Devising Strategies Nationwide Service Network to improve Service Quality Level, Timely response, and qualitative solutions.
Suggesting improvement in Policies & procedure revisions for operational and administrative control of Nationwide Service Team.
Hands-on technical and managerial trainings include new arrived models their functions, operations, and remedial actions and in order improve competencies, interpersonal, and communication skills of service team. • Rectification on production line of manufacturing faults of sold, communicated by customers analyzed by nationwide complaints data. • Co-ordinate with OEM (Supplier), for the technical assistance and product Knowledge in Upcoming models and distribute to nationwide service team.
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• Controlling Warranty cost through correct parts issuance due to faulty product in sold units, inspected by Service team and onsite analysis for the failure to provide feedback to the Quality.
• Managing proper standardization and calibration of tools equipment’s like gauges, charging leads, panels, cylinders, and other instruments to ensure standardized and safe workplace.
• Assuring the implementation of 1S0 9001 quality management system requirements in order to follow work instruction and documentations according to the implemented procedures.
• Formulating warranty complaints data sheets of nationwide complains to safe warranty issuance and rectification of top 10 faults with assistance with quality assurance department.
PROJECTS & ACHIEVEMENTS:
Attended 5 Days Training In Rome ITALY “Service Manager’s Workshop” organized by De-longhi-Kenwood UK, for the product knowledge and Technical Support.
Managing daily production quality by auditing process quality and minimize defects occurs at the production Line.
• Organizing work Sampling by performing process study of each process in order to improve production capacity
• Analyzing process defects & efficiency of worker to control end product quality & efficiency of the worker.
• Controlling revisions of documents like work instruction, operation procedures, Safety Manuals, to be more precise and easy to perform smooth line operations.
• Perform Different Lab testing for the plugs & Socket according to the IEC-60884 Standard.
• Responsible for the implementation of Lean Manufacturing techniques to continuously improve production line by reducing all 7 types of waste from the production.
• Managing proper standardization and calibration of tools equipment’s and other instruments to ensure precision of product quality.
• Ensuring 5s & Safety compliance Safe Place to Work To everyone by reporting accidents and unsafe Acts.
Technical and Operational Activities.
• Leading a pool of around 30 employees of different grades including Engineers, Supervisors, outdoor/indoor Technicians Skilled and Unskilled Labor.
• Looking after overall department’s Operational matters (Refrigerators, A.C repairing, services, and its remedies).
• Responsible for the implementation of Lean Manufacturing techniques to continuously improve the productivity of technical team.
• Assuring the implementation of 1S0 9001 quality management system requirements in order to follow work instruction and documentations according to the implemented procedures.
• Managing proper working and calibration of tools equipment’s like gauges, charging leads, panels, cylinders, and other instruments to ensure standardized and safe workplace.
• Ensuring safe place to work for everyone by reporting accidents, near-misses and unsafe acts.
• Controlling smooth operations of fault diagnostics of rotary and reciprocating compressors as per standard for proper feedback to supplier for improvement.
• Participates in technical audits and compliance assessments, and follows up on closure of remedial action plans to attain best results.
• Ensuring Safe operations of Refrigerant 134a, 404a, 290, 22a, 410, 600 during repairing, and their nature of hazard for human safety.
• To organize daily work management at shop floor and Field.
• Conducting hands-on technical and managerial trainings include new arrived models functions, operations, and remedial actions and in order improve communication, and interpersonal skills in my team to get batter customer satisfaction with improve technical competencies to perform as per expectations.
• Contribute to a co-operative working environment and cultural decorum within the department.
• Controlling 5'S implementation & ensuring HSE Activities.
Managerial Activities:
• Managing operational matters, in order to provide best and timely services to Local customers, corporate customers & dealers.
• Ensure daily, weekly and monthly reporting on time with proper data and targeted SQL service quality level.
• Organizing Monthly Meeting with corporate customers like Engro, uniliver, and walls to realize their issue in order to provide best services.
• Controlling Redo complains from customer in order to safe loss of resources, money and annoyance level.
• Ensuring targeted spare parts sales (Compressors, refrigerant, and other refrigerating Components).
• Responsible of financial growth to make profitability through parts sales and generating revenue by providing services of Split ACs, refrigerators, washing machines and microwave ovens to corporate and other customers;
• Controlling Administrative matters such as monitoring assets, manpower and maintaining decorum in staff as per company’s policies and procedures.
• Ensuring customer, dealer satisfaction through timely response of complains and rapid visits of market.
• Managing inventory through monthly demands of required over 200 parts to ensure availability on time.
• Looking after accounts matters in order to maintain daily and monthly expenses.
Dawlance Group of Companies.
Designation:- Assistant Service Manager September 2012- to Date
Responsibilities
• Controlling warranty cost with respect to the complaints of Refrigerators, air conditioners by customer side & summarizes technical information provide to the factory.
• Manufacturing faults diagnosing in the branch & usage of Parts against costumer complaints reporting to the Head office.
• Managing Branch operations to provide good after sales services & customer satisfaction with aspects of every costumer is a vital costumer on the city level.
• Evaluating product quality against complains data with respect to the process, specifications, refrigeration components & operating procedures
Procon Engineering (PVT) Ltd.
Designation:- Engineer Development June 2011- to - August2012
Responsibilities
• Planned and scheduled the localization / development projects; from TSA (Tooling Start Advice),
concept design, tooling, prototypes and evaluation of parts (Off Tool Sample)
• Negotiated and motivated local vendors and off-shore resources in timely procurement of material;
special components from Japan, Thailand for sharing their productivity.
• Directly coordinated with OEM's for in house parts development as per required Engineering
Standards and assured all Quality aspects for the Mass production.
• Product pricing (costing) involving in house resources, assets usage of the labor and Material.
• Trainee Internal Auditor for the Implementation of ISO 9001 Quality Management System (ISO/TS
16949) Standards for the automobile industry.
Professional Projects & Achievements:
• Worked on development of special Project HILUX, Army variant (single cabin & double cabin)
• Worked on Honda CIVIC Seats over all development.
successfully completed the Bachelor degree in (industrial engineering & Management) from a reputable university of Pakistan with 68% GPA & various engineering & managerial subjects Related to Designing, Development, Co-coordinating, Controlling,& in different departments of an organization.
2004-2006 Intermediate: H.SC. part I & II (Pre- Engineering) BISE (HYD)