Highlights:

Skills:Lean Manufacturing, Continuous Improvement, CAPA, APQP, Line Balancing, Value Stream Mapping, Quality Control, Cause & Effect analysis, SAP, Auto CAD, 5S, Total Productive Maintenance, Costing, Zero Base Analysis

Process Lead 01/2023 - current
The Hershey Company, Hazleton, Pennsylvania United States
Industry: Food Manufacturing
Working as Process Lead in panning production business unit to look for opportunities for process improvement and control standard production Efficiency & quality
Responsible for the development and management of equipment centerlines - (Optimal standard production parameters) to achieve standard Production & Equipment efficiency. • Lead Autonomous Maintenance, Kaizen, and 5S events as the Continuous Improvement leader of the Hazelton facility to improve equipment performance, reduce waste and improve visual management. • Drive daily problem-solving and data driven planning efforts by performing 5 Whys, CAPA, and Cause & Effect as the problem-solving leader for the business unit. • Lead financial valuation for pipeline items, CI savings, capital projects, and new item costing to eliminate bottlenecks and improve productivity. • Assist Production in rapid change-over activities through standard step-up card/job aids to ensure the reduction of non-production time and closely follow the Master Sanitation schedule. • Responsible for training and coaching operators and mechanics on PEP & GMP requirements to ensure Food Quality & Food Safety is the top priority of the Plant.--
Process Engineer 8/2022 - 12/2022
Polyglass USA, Hazleton, Pennsylvania United States
Industry: FMCG
Procees Engineer responsible to own the production quality & productivity
• Led plant-wide Continuous Improvement projects and workshops to identify opportunities of improvemens for plant efficiency. • Developed Standardized Work Instructions and Quality Protocol documents for operational control and improved work practices for Production Process & Control. • Provided hands-on technical and managerial trainings related to new equipment, chemical mixing, production process, packaging systems, and Quality & Safety procedures to all levels of employees. • Formulated and analyzed data sheets, reports from Power BI, and CMS according to different KPI’s to reduce 2nd Grades and downtime and ensured the Product Quality Levels of the Production process. • Conducted multiple meetings on performing 5 Whys, Root Cause Analysis and CAPA activities related to plant-wide Safety incidents and Quality problems. • Coordinated with Production and Procurement teams in supplier assessment and standardization to ensure excellent supplier quality.--
JCMS Specialist - HPT Engineer 02/2018 - 06/2021
Johnson Controls Inc., Dubai, Dubai United Arab Emirates
Industry: Building Technologies
a continuous improvement Engineer responsible for Lean manufacturing implementation with all areas of manufacturing, like Manufacturing, production, process, quality, material control, & labor management
Managed a team of approximately 200 employees of different grades (Co-coordinators, Supervisors, and both skilled and unskilled labor). • Led and trained teams to increase multitasking skills and standardized work procedures to meet Johnson Controls’ high manufacturing system standards. • Served as the leading champion and Six Sigma practitioner of Continuous improvement & Value Stream flow, in order to reduce cost, time, and work-in-process inventory flow and cultural behaviors to maximize productivity as per JC’s standardized manufacturing system. • Managed overall sheet metal manufacturing process for manufacturing HVAC parts such as diffusers, linear diffusers, dampers, linear bar grilles and the assembly area of all Products. • Managed in-house fabrication area (Lathe Operations, Welding, Cutting, Shearing & Milling) for developing new parts according to drawings, and implemented methods to generate ECRs (Engineering Change Requests) for developing new sheet metal products. • Improved on Product and Process systems by utilizing different Process Improvement tools such as DFM (Design for Manufacturing), Line Balancing, Value Stream Flow and other manufacturing methodologies in the assembly line area to minimize cost. • Ensured daily and monthly Production KPIs were achieved 100%, with assurance of on-time delivery to the customer as per lead time within allocated resources. • Held responsibility for Production Planning & Execution at maximum efficiency, meeting all Quality standards as per ISO 9001.--
Productivity & Quality Engineer 02/2016 - 09/2016
Micro Automation Industries, Dubai, Dubai United States
Industry: Electrical Electronic Manufacturing
worked as quality Engineer performed Product Standard Testing incoming material inspection & Production quality control.
Managed daily production quality by auditing process quality and minimized defects at the production line. • Organized work sampling by performing process study of each process in order to improve production capacity. • Analyzed process defects and efficiency of workers to control Final Product quality. Page 3 of 4 • Oversaw revisions of documents such as work instructions, operational procedures and Safety manuals to be more precise and easier to perform line operations. • Performed lab testing for plugs and sockets according to the IEC-60884 Standard. • Responsible for the implementation of Lean Manufacturing techniques in order to continuously improve production line by reducing all types of waste from the production process. • Managed proper standardization and calibration of equipment (i.e. gauges, charging leads, panels, cylinders, and other instruments) to ensure a standardized and safe workplace. • Ensured 5S and Safety compliance by reporting any accidents and/or unsafe acts.--
Service Manager 12/2014 - 01/2016
Pak Elektron Limited, Karachi, Sindh Pakistan
Industry: FMCG
Manager of Service center for daily complaints managements, parts Management & branch Service & sales revenue
Provided departmental oversight of technical Operations for refrigerators, AC repair and services. • Ensured safe operations of Refrigerant 134a, 404a, 290, 22a, 410,600 due to hazardous nature to humans. • Managed operational matters in order to provide best timely services to local and corporate customers, and • dealers to achieve maximum customer satisfaction. • Inspected and analyzed system efficiencies, determining condition of existing systems and verifying operating parameters for standard repair and performance. • Ensured on-time daily, weekly and monthly reporting with proper data and targeted SQL (Service Quality Level). • Organized monthly meetings with large corporate customers like ENGRO, UNILIVER, and IGLOO to understand and address any issues in order to provide the best possible customer service. • Executed targeted spare parts sales processes for compressors, refrigerants and other components. • Responsible for financial growth and profitability through parts sales, and generated revenue by providing services of Split ACs, refrigerators, washing machines and microwave ovens to corporate and other local customers. • Controlled variety of administrative matters such as monitoring assets, manpower and staff decorum as per company’s stated policies and procedures. PROJECTS & ACHIEVEMENTS: • Led problem solving efforts for a deep freezer / stucco sheet damage issue by designing eutectic plates and reduced warranty cost by approx. $1 million/year. • Contributed to an annual increase of 10% financial growth by achieving sales of $5 million.--
Assistant Manger Services 08/2012 - 12/2014
Dawlance Group of companies, Karachi, Sindh Pakistan
Industry: FMCG
Managed Daily complains managements, Workshop complaints Management, product development aftermarket sales, franchise revenue management.
• Managed operations in home appliances sector of in-house and at different franchises by ensuring timely and qualitative services 868to the customer. • Guaranteed customer and dealer satisfaction through timely responses to complaints and rapid on-site visits. • Oversaw implementation of IS0-9001 Quality Management System policies and procedures. • Analyzed warranty revenue complaints in order to control warranty costs of branch; looked up compressor issuance and gas charging and managed P&L of branch. • Prepared EDFR (Early Detection Fault Report) for both in-house and onsite product related issues and provided feedback for improvement. • Ensured monthly service revenue targets were achieved by managing smooth operations of in-house and franchise support. PROJECTS & ACHIEVEMENTS: • Achieved 100% customer satisfaction in year to date and earn incentive of 5000/month and by 60000/year. • Marked 15% growth with of revenue generation in Year to date. • 60% same day completion of every complaint in year to date with respect to 50% of benchmark.--
Development engineer 06/2011 - 07/2012
Procon engineering, Karachi, Sindh Pakistan
Industry: Automotive Manufacturing
Trainee Development engineer, Worked for the product costing product Standard development, Parts development with overall APQP process
Planning and scheduling project of the development of localized parts from starting drawing to TSA’s • Designing Fixture concepts, tooling, and reverse engineering from evaluation of part to its OTS (Off Tool Sample) provided by OEM (Original Engineering Manufacturer). • Controlling PIS (Part inspection standard) and quality check sheets and final controlled drawings and distribute quality assurance department to assure per product quality during mass production. • Preparing Costing sheets of parts including tooling, press operations and overheads calculation in order to provide possible rates to OEM. • Arranging special CKD (complete knock down), components from Japan, Thailand for sharing with quality, designing, Tools & dies departments. • Coordinating with OEM’s for in house parts development as per required engineering data, drawing, standards and assured all quality aspects for the mass production. • Trainee Internal Auditor for the Implementation of ISO 9001 Quality Management System (ISO/TS16949) Standards for the automobile industry. • Developments of quality standardization, flow process charts, control plans, failure modes effects and analysis for in house manufacturing. PROJECTS & ACHIEVEMENTS: • Led the project of development of HILUX, Army / US Embassy variant (single cabin & double cabin). • Led the project reverse engineering of Honda CIVIC 2HC seat development including Costing, Drawings, Fixtures, Inspection Standards and Parts. • Team member of proper implementation of Toyota Production System (TPS) to ensure total Productive Maintenance in mass production area to reduce waste.--