Heading Production plants i.e.

GCF A (Stranded Cable Feeding Plant, both Copper and Aluminum).
GCF B (Low Voltage – General Wiring Plant).
PCF (Power Cables and Medium Voltage Plant).
CRP (Copper Rod Furnace Unit).
PVC (Compound of different variety - cable grade)

Process Engineering Department:

Facilitated all manufacturing plants in all kind of process challenges, and directed more than 230 employees including Management Staff and Unionized Workforce (CBA).
Reported to Director Operations / Supply Chain and headed Operations meeting comprises of Production, Process, Maintenance, IR, QCD / Technical, Purchase, Planning, and Marketing Services.

Key Responsibilities

Developed KPIs, devising plans to achieve sales demand through the deployment of efficient teams, defined Production Strategies to increase equipment utilization in cost-effective manner.
Implemented World Class Manufacturing strategies via Lean Six Sigma (Green and Black Belt Projects), measurement through OEEE and keep alive Continuous Improvement drive through Kaizan.
Built Medium to Long term ( 5 year) expansion plans based on Sales forecast, formulated Annual Budget Cycle, CAPEX planning & implementation. Project management based on Feasibility studies.
Strategically positions to perform supplier negotiations on purchasing, installation and commissioning of new machines, as well as negotiations with active CBA on COD and day to day operational matters
Ensured appropriate Training & Development (that includes Training Need Analysis, Training Plan and Execution)

Key Achievements

Increased production output from an average of 450 MT per month to 835 MT in 18-months’ time
Achieved OEE from 37% to 61%, and are progressing.
Reduced copper wastage from 3.2% to 1.7%.
Reduced average 5% BOM by re-engineering of manufacturing processes and cables construction.
Achieved WIP from 450 MT to 115 MT.
Achieved on Time Delivery (OTD) performance from 62% to 82.3% in 8 months target.
Successful negotiations with suppliers on purchasing of new machines, installation, and commissioning.
Achieved successful development of new cable families like PVC 105, LSZH, HFFR, ACCC.
Increased reliance on self-generation to decrease the conversion cost, also various energy consumption projects

Scope: DPL1, DPL 2 plants in Karachi and URIL Plant in Hyderabad

Exercised hands-on approach and effective controls to manage the product Quality, Internal and External Quality Cost, Labs, Calibration, Process Engineering, and Continuous Improvement program.
Established quality systems, on-time warranty analysis, and attribution and tear-down analysis to identify the process strength, also coordinate with concerned departments for necessary corrective and preventive actions.
Rendered a keen eye for details to review the quality department MOPs like Internal PPMs, Customer End PPM, Part inspection PPM, Cost of non-conformance, Kaizen, Safety, etc.
Reviewed and revised plans and confers with research and support staff to develop new products and processes.
Carried-out interim, corrective, and preventive actions for customer complaints received and submit preliminary action, root cause analysis (8D analysis), Containment action, effectiveness monitoring reports to the customer.
Generated QPC report, Defects, and Analysis, MIS Reports, Process Audit Report, Product Audit Report, Layout Inspection Report, Teardown Analysis Report Etc. Departmental strength is about 185 from all three plants.
Established strong working relations with other functional managers to ensure seamless execution of all operations.

Directed all functions and operations related to production (LV & MV Plants) and Process Engineering departments.
Established Plant Policies & Procedures, approved plans for achieving planned output, Budget preparation & control spending, Material efficiency, Engineering effectiveness, and fostered a well-trained production team;
Built strong working relations with other functional managers, also delivered weekly and monthly meetings/ presentations to CEO on Plant performance and results

Key Achievements

Successful completion of plant expansion projects (Installation & commissioning) and increased capacity from 2000 M Tons to 3200 M Tons for Low voltage cable plant.
Increased Machine efficiencies from 82% to 97% by deploying OEE model in both Plants and reducing a substantial percentage of waste (i.e. from 3.5% to 0.65%) in 14 months.
Recycled 100% PVC sheathing waste in the bedding process with a ratio of 50 / 50 percent.
Worked on manpower plan and reduce 7% of production staff by automation and relocation on machines this was successful by using Time & Motion Studies and through the development plans of the workforce.
Production of single-core HV cables (66kv, 110kv & 132 kv) and get certification form KEMA (Netherlands).
Acknowledged by senior leadership at the time to leave the company, received special thanks & appreciation letter from Managing Director of the company.

Professional Career started as Production Engineer in Lamp Factory for 02 years. Later Promoted to Dy. Manager Process Engineering, then last position was Manager QC & Process Engineering.