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IdentityMBA(operations management)/B.E(Electronics & T/C) , Member of Advancing Productivity Innovation Competitive Success American Association for operations management & undergoing CSCP (supply chain management ) course in Dubai.
OBJECTIVE: Seeking Plant/Factory manager role in the functional domains of manufacturing/operations/engineering/production & planning/ Project management/ Plant Management /supply chain management in modernised FMCG manufacturing companies in Asia & Africa continent. Reports to GM & board of directors in UK.
PROFILE:
20 + years of career success in engineering , maintenance, production and project management domains predominantly with FMCG product manufacturing MNCs in Asia (India, Srilanka, Phillipines, Iran & UAE) & Africa (Egypt). Expert in start up projects, manage plant engineering-production, warehouse, quality functions. Experience in managing old plants able to turn over by implementing tools like lean management, tpm, tqm. Smart thinker & fast learner with flexibility & result orientation.20 years in FMCG companies like Coca cola India+Aujan cocacola Beverages Dubai (8.5 years), Arma foods Egypt(7 years) ,Ahmad Tea London FZE UAE(2.5 years & progressing).Result orientated team player positive attitude hands on approach is my strength,uses continuous improvement approach as tool. Completed MBA project on study of lean six sigma management implementation for continuous improvement in Aujan Cocacola beverages industries Dubai . Undergoing CSCP certification ,member of APICS.
Worked to complete green field project for Coca-Cola pirangut Pune plant for water treatment ,canning & pet plant(KHS/Sidel lines)(1995-2001).Kinley water for Bangalore Coca cola plant, Arma industries Egypt edible oil plant 400MT/day(oiltech Malaysia),soap & detergent plant In Cairo Egypt(Mazzoni & ballestra),(2001-2008).VDM process plant for Juice in Aujan industries Dubai, Alfa Laval non alcoholic beer filtration process plant in Aujan Industries Dubai(2008-2011). Tea PROCESS, blending & packaging unit set up in UAE in 2011-12.
Demonstrated professional excellence in introducing process improvements, process controls and identifying and overcoming weak links/ bottlenecks to enhance operational efficiency.
Core competencies in managing overall plant maintenance with prudent application of TPM, Computerised maintenance management systems including - preventive, predictive and cbm maintenance.
Strong credentials in managing manufacturing /maintenance and engineering operations in world’s best packaging & processing lines / plant for pp / bop/ can/ pet / glass/ pouch manufacture.
Proven track record of implementing start up /expansion projects in FMCG industries including- Edible Oil, Carbonated Beverage, Mineral Water, Hot Filling Juice, non alcoholic beer, juice with sacs & floats, Soap & Detergents and high speed filling, processing & packaging lines for Canning, Pet, perform making, Glass Lines Beverage Packaging, Juice, Water, Edible Oil, Tea blending –packaging, BMS, utility, beer filtration & manufacturing processes. Completed 251 KW solar on grid electrical power system to produce 440000 units /year.
Adequate experience in implementing ISO-9001-2000 quality systems and ensuring observance of HACCP, GMP, and Standards allied documentation. Team member for ESMA implementation in Aujan Dubai.
Acknowledged team leader, trainer and motivator with fine-tuned analytical and troubleshooting skills. Superior verbal and written communication.
Very good learner have worked in Asia & Africa continent with people of multicultural origin successfully (Coca-Cola India 6 years ,Arma food Egypt (Al said group)7 years ,Aujan Cocacola beverages Industries Co. Dubai UAE, Ahmad Tea London RAK free zone at present )
Setting up lean based manufacturing tea process blending & packaging plant in UAE for UK based MNC. Implemented A,P,Q,OEE measurement process on shop floor helping to continuously improve.
Visited tea industries in Sri Lanka, Moscow Russia, Iran for auditing the Ahmad Tea FZ LLC group companies & implemented lean six sigma management with objective of increasing efficiency, methodology for 8 waste identification & using DMAIC to set up objective & methodology to achieve the objective result.
Supported Aujan industries Iran to set up canning factory with lean principles(2009).
Complete experience of factory setup from building concept drawing, negotiating with RAKIA free zone for the factory setup, layout, negotiating UTICO for power & water connection, recruitment for engineering ,production & warehouse personnel, selection of equipment based on life time costing for the complete plant, designing & implementing BMS system for the plant for energy efficient process, making production planning, feasibility study of warehouse management system, inventory & spares management in 2011. Within six months of Factory operation (June 2012 to Dec 2012) in Ahmadtea Fz LLC we planned & received HACCP certification from SGS .
Setup Warehouse racking system, layout & material flow, lead team for planning & implementing warehouse management system, set up material handling system.
Setup engineering, Production & QC department, wrote job description, went to Philippines & India for recruitment (100 operators, technician, engineers).Arranged training schedule & implemented training from various OEM to get to planned OEE level of 70 in first year. As of Feb 2013 OEE is 74%.I taught electronics & scada basics in Egypt to higher technological college students as part for preparation for the recruitment.
Working as Plant Manager & engineering, production, warehouse, QC , planning & purchase is reporting to me.
Heads cross functional team for sales & order processing to align the marketing requirement, forecasted quantity, plant capacity, blending, sorting, loading & replenishment plan.
Heads cross function team for shipping department to align UK corporate office & UAE office for shipping schedule for incoming & outgoing containers(200 /month).
Implemented incentive matrix for the factory operation .Implemented DMAIC principles for blending, reclaim process.
Part of team for management accounting for cost of goods produced, yield analysis ,reduction of wastage by methodology of 4R(reduce, recycle, reuse, repair). Improvement in BOM, inventory accuracy between WMS & ERP, inventory classification.
Did Capacity plan for production & warehouse in terms of SKU, pallet space, pallet movement, manpower & man hour. I have working knowledge of Navision ERP.I see reports for RM/PM/MRP/aged report/monthly report for departments.
Implemented 4 steps methodology for warehouse for VNA allocation, picking, inspection & loading containers.
Presently working on inventory optimization for RM & PM using production & inventory /demand planning/stock accuracy, pipeline inventory..
Budgeting engineering, production ,warehouse & qc departments for opex & capex.
*Establishing manufacturing quality standards, methods, facilities policies, and procedures.
*Charting out several safety measures for minimizing occurrence of accidents, fires, calamities; conducting investigations for determining the basic cause of industrial accidents.
*Monitoring the production efficiencies, raw material quality, implementation of GMPs, controlling fixed and variable manufacturing costs, releasing monthly operating plans and ensuring compliance with SKU level demand from supply chain.
*Managing the erection and commissioning of machinery & equipment, ensuring adherence to the pre-set technical specifications.
*Sourcing the vendors & conducting techno-commercial negotiations to finalise deals for project execution.
*Leading, mentoring & monitoring the performance of team members to ensure efficiency in process operations and meeting of production targets.
*Creating and sustaining a dynamic environment that fosters development opportunities and motivates high performance amongst team members.
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