Experienced Plant & Facilities Operations Management Professional with over 27 years of experience. Skilled at supervising, leading, and directing tasks to achieve optimal productivity and results. Experience in prior positions developed the ability to balance high productivity with high quality and effectively manage the factory team's personnel. Proficient in all aspects of factory operations, budgeting, organization, and management. Adept at motivating the team to meet goals and achieve exemplary productivity while maintaining high standards of quality expected of the products manufactured at the facility.
? P & L, Economic Modeling/Business Analysis
? Continuous improvement & Cost Reduction
? Supply Chain Management, Contract / Toll Manufacturing
? R & D, Innovation & Process improvement
? Plant Design, Project Planning & Management
? Plant Maintenance, Facilities, Utilities & Energy Management
? FMCG, Dairy, Food & Beverages
? Natural / Herbal Medicine Manufacturing
? Grocery, Confectionary, Backing, Roasting & Frying
? SD, RTD, RTE, RTC & Aseptic Packaging
? UHT, Pasteurized and allied dairy products
? Pulping, Concentrate, Puree and Extractions
? P & L Economic Modeling/Business Analysis
Professional Work Experience
Mitchells Fruit Farms Limited Renala Khurd Pakistan
Factory Manager 01 / 2023 – Present
Managing Entire Plant Operation ( Grocery, Confectionary, Pulping, Pickles ) including Planning, Production, Quality (QA / QC), Plant Maintenance, Engineering, Utilities and Project Management, RM, PM and FG warehousing, Plant Administration, HR and IR related activities including labor union issues, Fruit and Vegetables Contract farming and Seasonal supplies, Pulping Plant Operation, Vegetable (SAAG, Spinach, Corn, Peas,) Processing plant, Confectionary Plant Operations (Chocolate, cereal Bars, Hard and Soft Candies)
Key Achievement:
? Improved product quality by 30% through collaborating with quality control managers and implementing effective quality control processes
? Directed the overhaul of factory safety protocols, resulting in a 50% reduction in lost-time incidents, ensuring a safer work environment, and increasing employee morale and productivity.
? Managed a process re-engineering project to improve and consolidate end-to-end service processes; restructured communication flow among all departments and cut down paperwork by 75%.
? Streamlined processes, resulting in a 20% reduction in staff and increased production levels while improving staff utilization and induction of Coaching & training programs
? Collaborated with partners to review monthly financial results and increase profitability by 15% through strategic analysis and planning
? Developed a comprehensive product development roadmap aligning with market trends, resulting in a 25% increase in customer retention and a boost in market share within six months.
? Increased productivity by 10% through the development and implementation of industry-specific training strategies for new and existing employees
? Boosted employee morale and engagement by establishing clear direction and job expectations, leading to a 15% decrease in turnover rate and improved overall company culture.
? Maintaining compliance with SMETA, FDA, PFA, PSQCA, and allied bodies regulations & quality Control standards,
? Leading for Strategic Leadership, performance monitoring, process optimization, communication and team collaboration
Dalda Foods Limited Karachi Pakistan
Senior Plant Operations Manager 09/2018 – 01/2023
Plant Operations & Projects Manager 07/2015 - 09/2018
Project Manager 09/2012 - 06/2015
Managed Lahore Plant complete operations (Snacks, Dairy & Beverages plant) including Production Planning and Management, Engineering & Maintenance, Quality Control (QA / QC), R & D, Plant Administration, HR Function, and IR dealing with Govt. agencies, Toll Manufacturing, 3P Facilities / Service Provider.
Directed end-to-end project life cycle for a greenfield project from feasibility to commercial production, leading to a 20% increase in plant efficiency and a 15% reduction in production costs, Job includes Project Planning and Execution, Plant and machinery selection and souring, Civil and MEP work, Plant Installation and Commissioning, Product Development, Staff Hiring & Training, Dealing with agencies like WAPDA, SNGPL, EPA, EOPI, PESI, PFA, PSQCA, Certification Bodies
Orchestrated seamless execution of plant expansion projects, resulting in a 90% increase in production output and a 30 % reduction in overall operating expenses.
Key Achievements:
? Reduced plant safety incidents by 20% through strategic resource allocation and program management, resulting in increased productivity and cost savings
? Streamlined project processes resulting in 10% cost savings by working closely with Marketing and Sales teams to identify and meet customer requirements
? Spearheaded the planning and construction of new facilities, implementing processes and procedures that led to a 15% increase in operational efficiency
? ROI increased by 25% & Pkr 30 million saved annually by utilizing CEP/OCR & optimizing Parts Life cycle, leading to higher profits
? Developed cost-saving process by proposing and implementing supply chain mechanisms for Raw and packaging materials supplies with annual saving impact of up to 8% Annual 50 million/ Pkr
? Promoted 5S, WCM, TPM, Lean Manufacturing & HSE within the Manufacturing unit and TPM professionals training and development and established the program to cascade culture onto the production floor with feedback and action plans.
? Recruited, hired, and trained initial personnel, working to establish key internal functions and outline the scope of positions for the new organization.
? Trained and guided team members to maintain high productivity and performance metrics.
? Launched staff engagement, gender diversity, and cultural programs in addition to a robust reporting tool that increased operational quality.
Prior / Earlier Career
? Asian Food Industries Limited Raiwind Pakistan
Chief Engineer 02 /2011 – 09/2012
? Almorrell International Inc. Baghdad Iraq
Plant Operations Manager 09/2009 – 02/2011
Regional Maintenance Manager 11/2008 – 08/2009
? Qarshi Industries Limited Hattar KPK Pakistan
Engineering & Project Manager 03/2008 – 11/2008
? Haleeb Foods Limited
Maintenance Manager 12/2004 – 03/2008
? Noon Pakistan Limited (Currently Fauji Foods Limited) Bhalwal Pakistan
Assistant Engineering & Project Manager 02/2002 – 12/2004
? Binzgar CO-RO Limited Jeddah Saudi Arabia
Engineering & Maintenance Supervisor 03/1997 – 02/2002
Education / Qualifications
? BE Mechanical Engineering, 1996 NED University of Eng. & Tech. Karachi Sind, Pakistan
? Diploma: Operations Management (Ops) Alison Ireland
? Diploma: Human Resource Management (HRM)
Projects and Upgradations
? Completed Brownfield UHT Dairy Project at Dalda Foods Limited 2021
? Completed Greenfield Dairy Project at Dalda Foods Limited 2014 -2015
? Completed Green Field RO Water Plant at Dalda Foods Limited 2017
? Completed Greenfield Snacks Project at Dalda Foods Limited, 2015 – 2016
? Completed Greenfield Solvent Extraction Project at Dalda Foods Limited Karachi Pakistan 2013 – 2014
? Completed Brownfield Confectionery and Baking project at Asian Food Industries 2011
? Completed 02 Greenfield RO / Purified and Mineral Water Bottling Plant at Oasis Waters Inc., 2009 – 2010
? Completed Tetra Pak Section Up-gradation with 09 TBA Filling Line, Water Treatment plant at Haleeb Foods
? Completed Greenfield Dairy project at Noon Pakistan Limited 2004
Training / Certification
? FMEA (Failure Mode Effect Analysis) Advance Level Training from APPANAGE Pakistan
? Emerging Challenges in Maintenance Management Advanced level from Business Partnerz
? Inspiring Leadership Through Emotional Leadership from Da Vinci Trainers and Consultants
? Start-up of Food Processing from NPO Sri Lanka / APO Japan
? TPM / WCM Orientation Course from Compass Consultant Pakistan
? Green Productivity & EMS ISO 14000 E-Learning Course from NPO Pakistan
? Negotiation Skills E-Learning course from NPO Pakistan
? Human Resource Management E-Learning course from NPO Pakistan
? Lean Manufacturing & Production Innovation Training from SMEDA, NPO & APO
? Energy Efficiency & Management in SME's training from APO Japan
? Productivity Enhancement training from NPO Pakistan
? Improving Productivity Through Motivational Skills Training from NPO Pakistan
? TPM (Total Productive Maintenance) course from NPO Pakistan
? Energy Management & Energy Auditing training from NPO Pakistan ISO 22000 – 2005
? Food Safety Management Training (FSMT) from APO Japan
? ISO 9001 – 2008 Internal Quality Audit training course from NPO Pakistan
? OHSAS 18001 Training from AMD at Al Morrell Development Iraq
? HACCP Training from AMD at Al Morrell Development Iraq
? GMP & GHP Training Course from AMD at Al Morrell Development Iraq
? Project Planning, Scheduling & Monitoring Training Course from NIDA–TUSDEC
? HVAC Design Training course from NIDA - TUSDEC Pakistan
? TBA – 19 Operational Training from Tetra Pak Saudi Arabia
? TPA–19 Operational Training from Tetra Pak Saudi Arabia
? TBA - 19 Maintenance Training from Tetra Pak Saudi Arabia
? TBA – 08 Maintenance Training from Tetra Pak Saudi Arabia
? TBA – 22HS Operational Training from Tetra Pak Italy
? TBA – 22HS Maintenance Training from Tetra Pak Italy
? TBA – 21 Maintenance Training from Tetra Pak Pakistan
? AS 6 PREPAC Maintenance & Operation training from PREPAC France
? TA Flex 10D Operational & Maintenance Training from Tetra Pak Pakistan
? GE – Fanuc LM 90, PLC & Electrical Training from Tetra Pak Pakistan
? GEA UHT plant Operation & Maintenance Training from GEA TDS
Languages
? English, Urdu, Punjabi
? Arabic, Hindi