Techanical Manager
PepsiCo
مجموع سنوات الخبرة :17 years, 10 أشهر
In my current role as Technical / engineering manager, I am leading engineering function with a team of 30 engineers & technicians. I am responsible for operations & maintenance of entire potato chips plant consisting of processing, packaging, utilities, warehousing, cold storage, WWTP & facilities/ office block. I am also responsible for all capital investment projects, covering projects of productivity, operating necessity, new equipment installation and building extensions. I am also leading site resource conservation agenda, sustainability & productivity agenda, managing 200 MM PKR of annual R&M, 1000 MM PKR of utilities budget and spare & operating supplies inventory of 400 MM PKR for the site.
As a greenfield project manager; I was responsible for the delivery of the entire greenfield project from design stage till commercial run. I worked in close collaboration with sector, region and local business unit in ensuring that the project is delivered as per the PepsiCo standards and all applicable international standards.
The scope of this project was to be build a new Greenfield snacks facility in Multan to cope up with the ever-increasing sales volumes. With total investment of approx. $ 70 MM; this is a state of art snacks manufacturing facility in Asia Pacific ( APAC ) region. A team compromising of International consultants, OEM's, local MEP & civil contractors and PepsiCo local project team worked under me and the whole project was delivered safely within 14 months from ground breaking within the allocated cost and timelines
Following is the brief scope of work.
• Total land is 104, 000 sq.m which will have finished good warehouse, process & packaging hall, raw material warehouse, process and domestic wastewater treatment plant, utility building along with social and admin block.
• New multi zone potato processing line with all associated processing equipment from PepsiCo global OEM ( Heat & control, Flo-mech, KMG, Key tech., CDD, TNA )
• New Fried Extrusion line with all associated processing equipment from PepsiCo global OEM ( RND, KMG, Heat & control, CDD )
• Total 16 high speed packaging twins, 12 for PC and 04 for Kurkure from PepsiCo global OEM ( ISHIDA, TNA, KMG )
• Complete plant utilities covering air compressors, HVAC system, HT / LT room, nitrogen and LPG circuit, genets, steam boilers water reservoirs and RO treatment plant
• Complete FM global fire sprinkler network and LEED certification.
• Pant IT, safety and security infrastructure and associated network
More than $ 60 MM project were delivered in last 4 years while I am currently working on more than $ 100 MM projects. . Management of multiple key capital investment projects from conception through to completion for PepsiCo snacks facility.
Following is the list of some key projects
1. PC 32 Project - Installation and commissioning of new Process Plant
It was $ 12.8 MM brown field project which was delivered within 12 month with zero LTI. A new potato chips line was installed which boosted PepsiCo PC portfolio capacity by 50 %.
2. KK Capacity enhancement
Capacity of Kurkure line was increased to 15 % within $ 2 MM Capex without any impact on fuel consumption.
3. Packaging twins
Packaging capacity enhancements were doing frequently in order to manage sales volumes / splits.
Two high speed twins installation and commissioning Jun 2014 - Capex - $ 1.4 MM
Four high speed twins installation and commissioning Dec 2014- Capex - $ 2.8 MM
Three high speed twins installation and commissioning Dec 2014- Capex - $ 2.2 MM
Two high speed twins installation and commissioning April 2013- Capex - $ 1.4 MM
4. Sustainability Projects
Various small Recon- sustainability projects were delivered
5. FM Global firefighting system - Plant HPR Rating
Installation and commissioning of firefighting sprinkler network as per FM global requirement. Total investment was approx. $ 4 MM while the project lasted for two years.
6. New Finished Good warehouse
The scope of this project is to Rebuild the Finished Good Warehouse (FGWH) building together with Racking storage system, to provide storage space for 12, 000 pallet positions . Total project cost $ 4.7 MM and project was delivered in one year.
7. Biomass Boiler
The scope of this project is to install a 18 tons per hr @ 28 bar (G) Bio Mass Boiler steam generation plant, together with all operational & safety accessories. Steam heat exchanger will be used to heat VO for PC 50 and KK processing lines while condensate recovery system will be used to run absorption chiller.
This plant substituted LPG to Biomass fuel and will generate net annual savings of $1 MM. Following is the brief scope of work.
8. Automated Stacking And Retrieval System - ASRS
The scope of this project is to install Automatic Racking system within the New Finished Good Warehouse facility at Sundar Snacks Plant Pakistan. This project includes installation of racks for pallets storage, automation & crane system for pallets handling & software and controls for inventory management. With total capex investment of $ 7.4 MM ASRS system will be the first of its kind in Pakistan and will give pallet storage space of 12, 780 and $ 0.5 MM annual productivity to the business.
9. PepsiCo Multan Greenfield Project
The scope of this project is to be builds a new Greenfield snacks facility in Multan to cope up with increase in sales volumes. Total project investment will be $ 60 MM while project will be delivered 18 months. Following is the brief scope of work.
•
10. Miscellaneous other projects
• Complete office block renovation and construction of new offices
• Plant HVAC system upgrade by adding a new electric chiller and several AHU’s
• Electric lift installation and commissioning at Admin block
• Admin security system upgrade and access control system
• KHX tube bundle replacement
• Air compressor installation and commissioning
• Carry out Plant maintenance activities, in accordance to the master maintenance plan on following equipment.
o Potato chips plant - Fresh hoppers, submerged barrel washers, peelers, slicers, fryer, seasoning system, distribution system )
o Non potato chips plant - Five random extruders one schaff line and associates equipment
o Packaging equipment - 48 high speed and normal speed bagmakers, KMG distribution system, tapping / packing equipment
o Four diesel genset ( 1 MW ), five air compressors ( VSD 75 & 90 KW ), 4 TPH steam boiler, one VAM chiller and one electric chiller, KHX ( Clean heat exchanger, 6 air handling units.
o Main water pump room, potato cold storage, vegetable oil, nitrogen & LPG network.
o Waste water treatment plant
• Manage a technical stores inventory of PKR 200 MM PKR.
• Monitoring & controlling an annual maintenance budget of around PKR 100 MM PKR
• To ensure maximum uptime of all process and utilities equipment.
• Ensure compliance to Water and Energy consumption KPI’s
• Played lead role in promoting a continuous improvement culture in Engineering along with other team mates.
• Launched Kaizen process across the factory and developed a robust plan for promoting continuous improvement culture all across the factory.
• To ensure that daily, weekly and monthly production plans are meet as per company’s AOP.
• To manage and control daily and weekly demand requirements in such a way that it drives cost, quality and efficiency.
• To effectively utilize and engage more than 20 frontline employees in both routine and non-routine activities
• Assess all packing machines, weighers, KMG system etc for proper operation.
• Effective utilization of labor hours to maximize product yields and to minimize waste.
• Prepare maintenance plan of all equipment relating to packaging in close liaison with engineering department and perform monthly Health Checks.
• Accurately compile and analyze shift wise production KPI report on daily basis.
• Maintain GMP and safety of the plant as per PEPSICO standards and to qualify all external and internal audits ( AIBI audits, HACCP, ISO compliance ) .
I have joined Unilever Pakistan Foods limited in Dec. 2007 and worked in engineering department as a project engineer for first six months. Currently I am working in production department as a shift manager.
Engineering Experience:-
• Installation and commissioning of 5TPH boiler
1. Finalized Engineering drawings & Scope of supply of different vendors.
2. Coordinated and successfully completed various boiler commissioning tests like hydro test, boil out etc.
3. Took lead role in conducting Boiler HAZOP and Project was completed with Zero Injury.
• Installation and commissioning of LPG circuit.
1. Installation of LPG Circuit at site after finalizing drawings & Scope of supply.
2. Negotiations with Contractors for timely completion of Jobs.
• Comparison of different fuels
1. Comparison of LPG, N.G and diesel. Saving of 5 Million was generated by it.
2. SKU wise steam was calculated thus facilitating sku wise cost allocation.
3. Line losses was minimized by rerouting, leakage reduction and insulation.
• Plan Maintenance
A comprehensive schedule of plan maintenance for the whole plant was prepared in consultation with all stake holders.
Production Experience:-
Following is the breakdown of my key responsibilities.
•Close coordination with all departments for timely manufacturing and delivery of quality products in compliance with safety, GMP and hygiene standards.
•Ensuring efficient and optimum utilization of plant equipment and resources (manpower and material).
•Regional Reporting on Alignment of Metrics And Information System ( AMIS ) as well as on Manufacturing Excellence.
•Working as a TPM 5S co-ordinator in close liaison with all zone champions as well as assisting KK pillar Leader in improving OEE and reducing R.M and P.M wastages.
•Monitor all processes, procedures and recommend improvement aims to achieve optimal rate, enhance productivity and yields.
I am working in DESCON Engineering Limited since March 2007 as a Proposal Engineer in EPC (Engineering, Procurement & Construction) department. Following is the detail of my job experience.
•P & I.D and Layout preparation
•Preparation of Bill of Quantities, Proposal Document, Level II schedule for Project & costing of complete Project
•Worked on the Technical and Commercial Proposal of a wastewater and a Reverse Osmosis project
•Preparation of the comparative statement of different quotations from the vendors and coordination with the vendors
•Mechanical piping and procurement
•Frequently inspected production at the vendors and removed bottle necks if there was any
Worked on my final year project.
Worked on Feminix Waste Reduction.
Prepared a brief report on power division.
Executive MBA in marketing and Finance