Leading RTT/BCOS deployment for Barry Callebaut!

Transforming careers of international talents in Canada with specialized coaching​.

Key Responsibilities:- Responsible for SQDCM (Safety, Quality, Delivery, Cost, Morale) of Auxiliaries Business Unit of Philip Morris Pakistan thereby managing Filter Making department, Tobacco Feeders, DCS, ODMS, Case Sealers & Ripping Machine.- Responsible for deployment of 16 Week RTT in Filter Making Department. - Responsible for hiring, succession planning & development of 01 Process Lead, 01 Maintenance Lead, 03 Line Coordinators/Team Leaders (5 Engineers), 85 Non Management unionized and Contractual Staff. - Autonomously leading and setting the 24 hours direction for the business unit to deliver the business results- Responsible for Safety, Quality, Incident elimination, Cleaning, Inspection, Lubrication and Defect handling.- Driving performance through Loss elimination and continuous improvement.- Develop, lead and review the 90 days action plans to drive breakthrough results in machine performance.- Assure adherence to production plan and to all line objectives.Responsibilities Additional to the role: - Quality SPOC for Secondary Manufacturing Operations. - Phase 0 QBOS (Quality Behavior Observation System) tool owner. Responsible for its deployment in Philip Morris Pakistan Sahiwal factory under the umbrella of Q-Pillar.- SPOC from Secondary for all the internal/external Quality Audits.Key Achievements to Date: 1) A total of 260 perfect shifts & 33 perfect days in last Q4 '20, Q1 '21 & Q2 '21. (Perfect Day/Shift: ∞ MTBF, 0 unplanned Stop, 0 Safety/Quality Incidents)2) 264% Improvement in MTBF in Q2 '21 (From 184 mins to 671mins per day)3) 3% improvement in OEE/Uptime/Process Reliability Q2 '214) 41% Reduction in reject rate of Filter Makers in Q2 '215) 11% & 32% Reduction in energy numbers in Filter Department & DCS.6) Successful deployment of RTT (Run to Target) in Filter Maker Department.7) Deployment of AM Pillar and Qualification of AM Step 4.

Responsibilities: 1) Owns the Centerline, Changeover (RCO/SMED), and Change Management DMS’s2) Leads process definition to identify Centerline targets and document standards3) Analyzes line data to identify and prioritize loss elimination opportunities, owns integrity of Line Event Data Systems (LEDS)4) Develops and Improves the Line Loss Analysis (Process Reliability Current and Future State)5) Supports development and leads execution of the 90-Day improvement plan to deliver the OEE/MTBF glidepath through loss elimination.6) Leads root cause problem solving (IPS, UPS) efforts on key chronic losses for the line(s), Coaches teams on Centerline, Changeover, and Change Management DMS execution and problem solving skills7) Participating in Line DDS process daily to set priorities and allocate resources8) Owns the Centerline Management system for the department9) KPI's: Stops, MTBF (Meantime Between Failure), Process Reliability, Machine Uptime. 10) Leads TPM/process improvement teams focused on the reduction of downtime and loss elimination.11) Supports and coaches AM/PM activities within the department by providing analytics and developing standards.12) Applies advanced data & Reliability analysis leveraging tools such as S-curve and Weibull.13) Owns Reapplication management DMS. Achievements:1) Improved Daily MTBF from 2.5 mins to 160 mins2) Reduced unplanned stops from 600 per day to 24 per day.3) Reduced Changeover Variance by 25%4) Improved Uptime/OEE/Process Reliability by 6%5) MTBF record of 395 mins in a shift with 1 Unplanned Stop.6) Brought one Linkup of machines to top 10 of EE/Asia region during Run-To-Target Deployment in terms of MTBF & no. of Unplanned Stops (At level of Phase 0 sites) & won an Above & Beyond the Call of Duty Award.7) Built IWS Process Lead DMS capability in 40 equipment owners.

Key KPIs:1) EHS2) Quality (VQI & CPQI)3) Uptime/OEE4) Yield5) Reject RateResponsibilities:1) Immediate supervisor of 41 shift employees and responsible for their appraisal, performance, deployment and training.2) Manage the daily allocation of resources (equipment, people & materials) to efficiently, safely and cost effectively achieve the KPIs.3) Ascertain that finished products are manufactured in compliance with product specifications, Quality Management System standards (ISO 9001); on time and meeting consumer expectations4) Leading focused improvement projects by using Problem Solving and Lean Manufacturing Tools (Pareto, Fish Bone, 4M, POKA YOKE, TPM, KANBAN, 5 Whys). 5) Leading and reporting on the issues rectification, focused improvement and preventive maintenance of Business Unit machines in collaboration with Maintenance Dept.6) Carrying out weekly performance review meeting with team to promote continuous improvement and employee engagement culture for identification of improvement areas and assigning responsibilities7) Ensure operation in a safe working environment complying with EHS standards (ISO 14001 and OHSAS 18001) by striving for zero accidents through continuous coaching on safety behaviors8) Responsible for periodic Risk Assessment of Business Unit machines and timely mitigation of hazards9) Leading the practical implementation of process driven initiatives aimed at improved performance and achievement of targets agreed with production management10) Creation of brand wise monthly STPP (Short Term Production Plan) in coordination with Supply Chain11) Cross functional collaboration with QA on quality issues, Maintenance dept. for preventive maintenance, Engineering dept. for utilities provision and Logistics for availability of raw material and packaging material to ensure smooth functioning of production12) Cross-factory and cross-affiliate communication and collaboration for product and process improvement initiatives

Summer Internship included the job in Maintenance Department. 4 weeks of practical knowledge of Heat Exchangers, Turbines, Pressure vessels, Distillation unit, Compressors, Valves, Dew Point Reduction units. It included the study, understanding and practicalities involved in a process industry plant

Honda Atlas Cars is a leading automobile industry, Honda Atlas Cars (Pakistan) Limited is assembling two main models, Civic and City.Working and exposure of 5 different departments including, engine assembly line, vehicle quality, AF line (Body assembly, engine docking, complex parts fitting), Paint shop, welding shop.