Fakhar Ghayur Email & Phone Number

Karāchi, Sindh, Pakistan

- Evaluate and analyze (1 + 4) week production plan incorporated in ERP w.r.t capacity, floor stocks and stores stocks. Incorporate any change due to materials shortage or under/over capacity utilization.- Ensure that the production records are properly filled-in and signed by designated person.- Review batch variance/yield report with production manager and take appropriate steps for improvement.- To ensure that all food safety standards are implemented and that products are complying the required quality standards.- To coordinate with production manager for controlling the effective utilization of available resources Man, Material, Machine and Utilities.- To monitor the ERP reports, of raw materials, production, machine maintenance, finished goods, and wastage and prepare monthly analysis report for management review.- To Prepare and enforce health and safety policies to establish a culture of health and safety in the facility.- To evaluate reasons of delays in production orders and prepare report with improvement recommendations.- To Coordinate with Quality regarding QA Audits, CAPA, Complaints RCA, Market Returns and Trend Analysis Reports etc.- To improve productivity by taking continuous improvement initiatives. Identify, prioritize, and stimulate the reduction or elimination of non- value added activities.- To prepare audit report and present report to the management with gap analysis and improvement recommendations.- To manage the proper maintenance of all plants and machines in order to upkeep the assets in good working and aesthetic condition- To monitor and reduce the plant maintenance cost by implementing best manufacturing practices, training of staff and introducing latest technologies.- To suggest the CAPEX requirements for next year and ensure utilization of approved CAPEX budget as per approved timelines.- Analyze and control the maintenance cost through ERP.

Karachi

ACHIEVEMENTS:* Executed a project to decrease product processing time in 2020. Reduce 70% time for tomato puree processing (Modify the vacuum cooker for juice concentration). * Design waste water treatment plant to handle 70000 liters/day plant waste water in 2019.* Headed a project to install the fruit pulp and puree processing plant in 2019. Produce 30% of the required Mango pulp for the year 2019 - 2020.* Chaired a project to enhance the plant capacity by installing complete PET line for Hot fill juice in 2018. Successfully installed and commissioned 22,000 BPH plant on time. Save PKR.30millions by not selecting a turnkey project.* Planned & Executed a project to increase product recovery at processing end in 2017. Amplified 7% product yields in a span of a year & sustain that yield. * Launched a project to rise plant capacity by improving compressed air supply system in 2015. Boosted plant running capacity by 30%. Lessened 3% maintenance cost of compressed air distribution system. JOB DESCRIPTIONS:• To Manage the juice processing plant having capacity of 150,000 liters per day.• To facilitate in improvement projects and provide lean expertise.• To ensure implementation of ISO 22000, HACCP protocols during the processing operations.• To ensure plant OEE improvement and waste reduction.• To identify and resolve abnormalities and process bottlenecks.• To plan, deploy and execute lean activities to reduce cost.• To collect all plant data, develop comprehensive reports and classify trends.• To promote and facilitate business excellence activities through trainings.• To develop and implement process control norms.• To implement visual management system on shop floor and conduct 5s audits.• To scrutinize consumer complaints and to evolve problem solving techniques.

Karachi

ACHIEVEMENTS:* Devised a project to run the dairy & beverage plant within a specified operational cost.*Engineered a clean water source to ensure nonstop supply of water for daily operations.*Organized a project for erection and commissioning of 10GPM RO water plant, for mineral water line.*Redesigned air distribution system to ensure clean and continuous supply of air to the plant.*Restructured an electricity generation and distribution system to ensure continuous uninterrupted supply of electricity to the plant.Conserved 20% direct Utilities cost as a result of this project. * Kick start operational excellence derive and get following results. • Resolve product quality issues by developing quality team and implementation of basic six sigma tools like CTQ, VOC analysis. • Reduced 30% processing cost by implementing production plans and utilities improvement plan. • Redesigned operational workflow processes to maximize efficiency.PLANT CAPACITIES Milk Processing 35,000 liters/day Juice Processing 35,000 liters/day Butter Processing 10,000 Kg/day Butter Oil Processing 2,000 kg/dayJOB DESCRIPTION• Establishes and implement the SOP and KPIs for all plant sections.• Plan and implement preventive maintenance schedule for the entire plant machinery.• Reduce per unit cost of production.• Ensure smooth operation of RO water plant.• Ensure smooth and cost effective processing of milk & Juice at UHT plant.• Ensure the implementation of ISO – 22000 and HACCP on entire plant.• Train the staff to ensure cost effective production and low wastages of the raw materials.

Tando Adam

• Manage operations of following departments. a. Juice processing & Packaging 150,000 liters/dayb. Mineral water processing and packaging 15,000 liters/dayc. Fruit pulp Processing and packaging 100,000 kg/day d. Drinking Straw manufacturing 800,000 straws/daye. Electricity Generations 01 MWf. Compressed Air delivery 15 CFM 03 compressorsg. Water delivery 50,000 GPH• Plan & implement PMP of utilities to ensure smooth factory operations.• Worked as ISO team member for implementation of ISO 22000.• Establishes the Standards of Production and KPIs for all sections.• Ensure the implementation of ISO - 9001 and HACCP.• Ensure implementation of Process Standard Operating Procedure (SOP’s).

Shekhu Pura

Successful erection & commissioning of Dairy & Juice Plant. (Machinery Details)(PROCESS) Pasteurizers, Homogenizers, Cream Separator UHT Plant, Aseptic Tank, TBA 09/19 filling machines,Pumps,agitators.(OPERATIONS)Printers, straw applicators, shrink machines, Fork lifters.(UTILITIES) Boiler, Ammonia Chiller, RO Water Plant, Generators (CAT, Cummins)ACHIEVEMENTS:• Develop & implement Inventory management system.• Develop & implement supply chain management system for raw materials availability.• Develop Logistics department for efficient deliveries of the finished product.• Develop Quality Control department to ensure the manufacturing as per defined standard.• Develop Quality Assurance department for the manufacturing of market compliant product.• Develop recipes of following products. (Tea Whitener, UHT Milk, Nectars and juices, Flavoured Milk)JOB DESCRIPTION:• Responsible for the cost effective production and low wastage of the raw materials.• Ensure up to standards processing of Milk & Juice on UHT plant (PLC System)• Ensure up to standards packing of Milk & Juice on TBA 19/09 filling machines.• Ensure availability of raw materials as per production plan.• Design and implement Process Standard Operating Procedure (SOP’s).• Effective production planning to ensure the maximum capacity utilization.• Effective maintenance planning to ensure minimum down time on the machinery.

Bhalwal

• Production Planning and scheduling to enhance productivity.• Ensure up to standards processing and Packing of SMP, ISMP on multi effect evaporator and spray dryer.• Ensure up to standards processing of Milk & Juice on UHT plant (PLC System)• Ensure up to standards processing of Cream on UHT plant (PLC System)• Ensure up to standards packing of UHT Cream on TBA 19 filling Machines • Ensure up to standards packing of Milk, flavored milk & Juice on TBA 19/TBA 8 filling Machines • Plan and manage the processing and packaging of yogurt.• Supervising and motivating the under command team members• Check and maintain the documentation of production department.

Hattar Industrial Estate

•Control Process parameters on PLC system.•Prepare daily production report.•Write technical report about plant equipments performance.•Write shift performance report.

Sargodha

Worked as ISO 9001-2000 coordinator.Worked as Food safety member of HACCP teamRaw material planning.Production planning.Shift planning.

Hattar

• Worked as assistant quality management representative for the documentation & implementation of (ISO 9001 – 2000, ISO 14001 – 2004) • Maintaining the daily production record.• Manage the production as per production plan.• Inspection of machinery, for the planning of preventive maintenance.• Checking of raw material stock as per production schedule, and ensure availability of raw materials.

(Masters), Operations & Supply Chain Management, A

B.Sc, Chemical, A

Activities and Societies: Sub Editor of IET magazine B.Sc Chemical Engineering

F.Sc, Pre Engineering, C

Activities and Societies: Lead Planner for all social activities. F.Sc Pre Engineering

Matric, Science, A

Activities and Societies: Debate Team member Matriculation