Plant Manager/Manufacturing Manager
Unilever
Total years of experience :17 years, 4 Months
Unilever HPC Factory, Saudi Arabia
Providing leadership and management of the Production, maintenance, project departments and structure operational processes for processing & packing of Home Care, laundry Range, Personal care, soaps and Oral care production plants.
Developing programs and processes to optimize operational performance, identifying cost reduction opportunities, devising production and engineering strategies, improving profitability and meeting the Company’s financial objectives.
Leading a TPM/World class manufacturing culture that consistently drives and achieves its key performance indicators through the application of production and engineering organization standardization and optimization linked with Global guidelines, process improvement and performance enhancement to drive down costs while meeting quality and other standards.
Establishing performance objectives, clear expectations with improved Quality Assurance, Environmental & Safety management systems for further growth and development.
Accomplishments:
Developed team capability coupled with SMART targets which enabled TP/WCM score improvement by 42% in 08 months.
Developed and Implemented standardized maintenance organization structure, skill profiling, libraries and KPI’s across all plants.
Promote the implementation of reliability centered maintenance management strategies resulting in reducing maintenance expenses by 400k Euro.
Ensured a consistent deployment methodology across plant operations to comply with established weekly cost and budgets, resulting in significantly reduced cost by 1.0 Mn Euro.
Installed robust quality assurance culture by aligning team with organizational objectives; focused on minimizing top losses and achieved 01 ranking globally beating Japan.
Deployed E-Reporting for all Operational KPI eliminating papers and 15% nonvalue added activity from team leaders.
Devised and implemented technical operator program ensuring future capability building n resource pipeline.
Introduced performance evaluation system for Blue collars linked with factory targets and successfully improved plant efficiency by 2.7%.
Streamlined production planning & resource optimization processes resulting in savings of 866K Euros.
Initiated Females Friendly Production facilities for 02 production lines which improved diversity from 0% to 8%.
Implemented central control systems on compressed air and chiller network resulting 17% reduction in energy consumption.
Developed and implemented innovation process and Standardized all the personal care production facilities with global hygiene requirement and delivered the biggest innovation of Sunsilk on time in full.
Implementation of direct dispatch project for all logistics operation resulting in 7% reduction in WH operational cost.
Developed the HSE strategy in line with the Company strategy and ensured the alignment of the same with company vision and mission.
Directed all the resources and activities to support the HSE programs and Security function for KSA and Yemen, conducted safety induction and training programs and aligned with local and regional parties.
Delivered security solutions that integrate technologies, products, and services to create smart environments that protect people and secure assets creating environmental/sustainability agenda for reducing environmental impact to half by 2020.
Provided tailored HSE solutions that are designed to meet the needs of HSE key performance indicators (KPI’s) and created detailed reports and charting road maps for seamless integration of HSE program.
Achievements:
Revised the waste management processes to achieve Zero waste targets for land Fill for all operations across head office, WH and factories in Arabia saving 1.2 Mn Euro.
Bestowed with the King Khalid Award by King Salman for the extraordinary performance in HSE and Environmental management.
Contribute to the development and recognition as best Business unit for HSE performance for 6 Quarters in 3 years and centralized the HSE governance center to achieve superior HSE culture.
Instrumental in renovating KSA head office and aligning processes to be agile certified office in 12months.
Improved team capabilities in achieving machinery safety, risk assessment, emergency management and Process safety leading to 92% closure of hazards.
Designed achievable Crisis Management plan for all business operations with simulation exercises.
Devised robust waste management program to achieve Zero waste for Chamber of Commerce office.
Imparted public training for environmental protection in Chamber of Commerce and Modon attended by 27 industrial and university partners.
Transformed global processes to secure highest budgets for environment programs and delivered 07%, 13% reduction in water and CO2/ton respectively during last 03 years.
Established the 1st ever Road Safety Travel Excellence Centre with simulation and trained 100% employees.
Set-up the E-Services operations for the HSE Reporting, resulting in 100% compliance to HSE KPI’s reporting.
Developed and implemented Office Safety Program resulted into 70% increase in engagements.
Achieved 53% increase in SHE Training Manhours in last 03 years.
Lipton Tea Factory, Unilever Dubai, UAE
Key Responsibilities:
Managed all aspects of Maintenance, Projects and HSE ensuring the safest work environment for all employees of 2nd largest Tea Plant in the world.
Created a standard cadence mechanism and instrumental in consolidating the HSE management system, while leading team based continuous improvement projects, developing accountability and sustainability.
Served as a key point for facilitating safe operations, production and HSE concerning operational status of the facility and reduce the risk of uncontrolled hazardous work.
Provided timely professional advice regarding systems of work, objectives and plans of health, safety and areas of risk to protect workers from potentially hazardous work methods, processes, or materials.
Accomplishments:
Played a vital role in project management and delivering of the biggest expansion increasing capacity by 27% on time in full.
Lead the unit in to be nominated for HH Sheikh Rashid Bin Maktoum Award for achieving exceptional improvement in efficiencies, cost reduction, HSE and environmental performance.
Developed and implemented Zero Breakdown Approach encompassing Preventive and Predictive maintenance across 05 Sourcing Units globally.
Implementation of line wise maintenance budgeting with line leader’s ownership resulting in reduction of maintenance expenses by 280k Euro.
Revamped the waste management principles and Achieved Zero waste to land Fill status for the 1st factory and head office in gulf region.
Significantly reduced production cost by 15% through cost automation, production labor optimization.
Introduced vendor managed electronic based inventory management system resulting into 50% stock reduction.
Developed and deployed Hand In Machine program with complex LOTO systems, which was picked as best practice.
Designed and deployment of technical training center which resulted into the birth of OPTECH program globally.
Implemented improved and innovative Emergency Management system and reduced evacuation time to 90 Sec.
Spearheaded the team to ensure the unprecedented speed in installation and commissioning of a complete tea bag line with 08 tea bag machines and EOL equipment in just 07 Days.
Enhanced the speed of Perfecta from 407 to 420 t/m and delivered world fasted perfecta.
Unilever Ice Cream Factory, Lahore, Pakistan
Key Responsibilities:
Build, deploy, train and drive total productive management TPM across the plant.
Drive continuous improvement activities for maintenance for all factory equipment including utilities, process, MEP, Instrumentation, facilities and pack aging lines of ice cream factory.
Orchestrated a wide spectrum of activities for establishing flexible processes to improve machine efficiency, utilization and reduce waste, ensuring that the production is cost effective
Provided leadership and coordination for all plant operations by establishing plans, budgets, and result measurements as well as allocating resources; reviewing progress and making mid-course corrections
Accomplishments:
Revitalized TPM on the production floor by effective engagements through kaizen programs/competitions and delivered 84% score.
Led the effort to advance equipment efficiency of the plant from 75.4% to 83.4% through preventive and predictive maintenance management and deployment of reliability centered maintenance program.
Enacted a comprehensive capacity improvement program across production plant registered 12% improvements while eliminating the bottlenecks in production lines.
Enforced controlled mechanism for Repair & Maintenance reducing costs by 22%.
Significantly minimized RM wastages from 3% to .98% and PM wastages from 4% to 1.2%
Achieved saving 13.7Mn by initiating local development of spare parts
Delivered 02 Golden Lunches and 15 Innovation Projects with 100% OTIF
Reduction in engineering store stock by 19% by Virtual Inventory Management
Implemented Safety Assurance Model line concept having 100% fool proof guards and controls systems.
Achieved 95% compliance for Risk Assessment for all operations which was the highest among sister factories.
Achieved 90% Hazard closure rate for all Operations by implementing HSE Hierarchy of controls.
Key Responsibilities:
Provide feasibility, detailed engineering designs, cost analysis and installation options to management and ensure Contractor Safety systems are followed.
Spearheaded plans for efficient use of materials, machines and personnel for organizational growth. Reviewed operational costs/quality, modified production/inventory control programs, for profitable operations.
Directed expansion projects and coordinated with suppliers, field crew and subcontractors to ensure timely execution of projects.
Formulated growth strategies including project feasibility studies; detailed engineering designs; cost analysis and installation options, while ensuring Safety systems are complied with.
Achievements:
Implemented Contractor Safety program and delivered all projects with zero injury.
Set-up a fully operational tea packing facility within a short span of 8 months with a capacity of 10000tons/year and prevented sales loss of 20Mn.
Vital role in augmenting the capacity of DPG Tea factory from 12000Tons to 36000tons/year in 12 month and minimized cost by 15% low in Sindh region.
Streamlined processes and reduced 35% by creating cluster concept for sachet and pouch lines.
Key Responsibilities:
Administered entire operations of plant and performed overhauling, inspection and maintenance activities for all plant equipment.
Demonstrated technical knowledge in maintenance and operation and executing it within assigned budgets.
Achievements:
Standardized Planned Maintenance (TPM) activities, resulting in 20% increase in MTBF, 28% Reduction in MTTR and 4.3% increase in OEE.
Brought down the change over time from 6 hours to 50 minutes as well as improvised on machines capability to run flexible packing materials (Paperless) saving 20Mn.