Factory engineer / Manufacturing excellence manager
Unilever Pakistan Foods Limited
Total years of experience :14 years, 5 Months
Maintenance:
• Develop and Implement Maintenance Strategy
• Preparation and implementation of Preventive Maintenance Plans for the Whole Plant
• Reduce Machine Failure through Effective Maintenance Strategy
• Inventory Management For Efficient Working of Engineering Store
• Machine Improvements for OEE enhancements and New Launches
• Managing and controlling repair and maintenance budget (worth PKR 80 Mn) for the site
• Planning & supervising all contracted jobs to ensure the right quality and cost without compromising on safety
• Managing the vendor relationships & negotiations with Key Suppliers for execution of different saving and Infrastructure projects
Manufacturing Excellence Manager
• Establishment and implementation of Loss Trees in Process, Production and Maintenance Department
• Establishing system for Root Cause analysis to reduce failure Rate.
• Reformation and activation of circle teams in factory
• Responsible for conducting monthly TPM Steering with all Pillar Leaders to review overall TPM progress
• Pillar Lead for PM Pillar
• Downtime reduction through machine improvements and Staff training.
• Development and implementation of TPM Master Plan
• Capability development and training of teams on TPM
• Coordinate the CTT Savings as the Site CTT Coordinator
Deliver Unilever Sustainability Agenda and Projects
• Developing Project Feasibilities for Capacity Enhancement, Automation and Man Power optimization
• Coordinate with SUIT and Projects team for Project briefs, DCF working and feasibility reports
• Deliver the Sustainability Agenda through Energy Saving Projects and Plant Energy Optimization
- Plant Maintenance and resolving Electrical and Instrument Issues for whole plant
- Preparation and implementation of Preventive Maintenance Plans
- Inventory Management
- Preparation of Weekly and monthly Machine Mechanical Efficiency Reports
- Preparing improvement plants for increasing Machine efficiency
- Time and Manpower management
- Implementation of ISO9000, ISO14000, ISO 22000, ISO 18000
ISO Certification:
During the implementation of ISO 9000, ISO14000, ISO 22000, ISO 18000 worked on
-Improvements in record keeping and SOP updates
-Carried out Base hazard assessment and Risk assessment Study for E&I
-Environmental safety hazard assessment study and preparing of improvement plans.
- Sl-900 Project BOQ preparation
ordering, planning and execution
- Yogurt Line project:
BOQ preparation, ordering, planning, process development, P&ID development, Process analysis.
Core Responsibilities:
-Preparing BOQs for Electrical and instrumentation equipment,
-Project Supervision, planning, execution and commissioning of the project
-Preparation of SLD for MCC and Cable routing layouts.
-Load Calculations and preparation of Cable BOQ as per loads and cable routes.
Project Details:
1- Ice cream plant expansion project
- Extension of Main MCC.
- Integration of New process equipment in main PLC (Control Logix)
- Extension of Aging room, Production hall, Material Warehouse and Cold store.
- Installation and commissioning of Walter Cone baking machine.
- Installation and commissioning of Tetra Pak Big Drum Machine and NTFE Tunnel.
Core Responsibilities:
Production planning and management of
- Liquid Dairy Processing (Pasteurizers, UHTs)
- Powder Dairy Processing
- Juice Processing
- Evaporators
- Spray Dryers
- Tetra Pak Filling Machines
Preparation and improvements of
- Process Loss and Gain Reports
- Capacity Utilization and machine efficiency for Pasteurizers, UHTs and Tetra filling machines.
Design Project for CIP system for Ghee (oil Section)
- Made complete 3d-model of the whole area in SOLID WORKS 2010
- Pipe routing for the modifications and equipment space allocations were given using the 3d-model
- Preparation of P&IDs using AutoCAD 2010