Faizan Baig Email & Phone Number

Karachi, Pk

Karachi Division, Sindh, Pakistan

Leading the combined portfolio of Quality Assurance , Quality Control , development of localized parts and customer quality engineering , in the manufacturing function to align the quality objectives of products , services with the global quality targets /policy of the company in line with Kia & Stellantis global quality mission .Continually improve integrated quality management systems (ISO 9001,14001,45001) to maintain ISO certification and compliance with regulations by overseeing system audits of manufacturing facilities.Implement measures to ensure safety, quality, and compliance in manufacturing activities, resulting in a reduction in safety incidents and decrease in non-conformance rates for finished good . Observe customer interactions and proactively addressed technical concerns raised by customers, leading to increase in customer satisfaction scores Monitor Supplier Quality Audits and implement improvements, resulting in an increase in supplier performance measured by Correction Actions Completion and a reduction in production downtime due to local parts.Optimized Production Part Approval Process for new model development, and implemented supplier quality assurance manual in liaison with local part development division & vendors.Promote risk-based thinking and process approach while deploying lean, and six sigma tools for Kaizen, and long term sustainability initiatives in order to solve quality problems in the manufacturing process of complete car.

Pakistan

It is a key leadership role to streamline the performance of the plant focusing on the improvement of production efficiency and reducing non-value-adding business processes across the Body, Paint, and General Assembly Departments.Manage daily production KPIs inclusive of complex quality and productivity parameters such as Direct Pass Rate, Production Utilisation, and efficiency with various vehicle functional and aesthetic performance assessment criteria.Improve the built-in quality of body fit-outs, dynamic testing parameters & and functional performance of vehicles by giving expert oversight to cross-functional teams with reference to body geometry and general assembly operations. Assist the Head of Manufacturing in making timely decisions by creating dashboards, and templates, for collecting operational data from ERP systems for operational reports such as downtime, and production results from each department. Recommend methods to solve technical and people issues for productivity improvement and for uplifting working culture.Oversee the annual budget planning, and resource planning activities, and monitor the cost performance of operational expenses in the Production Function.

Karachi

I was hired as Project Manager in the start-up phase of this greenfield project to construct and commission a CKD automotive plant with 50,000 units of production capacity per year. The role transformed into production management after successful project completion, and at the onset of the Mass Production Stage. I have to play a matrix/hybrid role at times oscillating from Project Management to Production Management per the business need.In the Operations role, I was responsible for overseeing manufacturing policies and operations in the plant. I lead the production operations after hiring and training technical teams, collaborating with IT, maintenance, quality, and logistics teams to enable mass production readiness in all aspects.In the capacity of project manager, I was in charge of supervising the layout design of the plant as well as the design and development of the manufacturing facility. Monitoring the project master schedule, taking part in regulatory approvals, examining and negotiating contracts, preparing budgets for capital and operational expenses, and leading initiatives to introduce new products and improve output on existing assembly lines are my purview.I had to collaborate on multiple fronts with the local construction and design team, the technical team of Kia, the local business team, and the top management for the success of the project. The exposure has allowed me to understand the detailed design of utilities, and civil structures while working with MEP design consultants, Architects, and Civil design teams as well as the construction companies for the construction phase of the project.Working with equipment manufacturers for machine procurement and commissioning also helped me build my technical core in plant design, layouts, and machine specifications for welding, painting, and general assembly operations. The experience equipped me with a holistic managerial approach to the development and operation of a manufacturing plant.

Saudi Arabia

Lead a team of 150+ members across various departments to achieve manufacturing excellence by focusing on quality, safety, and productivity KPIs as per the production plan. Work closely with Engineering and R&D departments to design fixtures for the assembly process, reduce setup time, re-work, and inventory, resulting in more efficient and effective production processes.In addition to technical expertise, use people skills to steer the training and development initiatives for the workforce by inviting subject matter experts from machine suppliers and technical partners.Coach the team on tools and techniques of Lean production systems, and job rotation within the department, and identify opportunities for cross-functional collaboration to optimize inventory levels and drive production process improvements.Implemented departmental procedural compliance for production planning, control, and monitoring of job flow on the shop floor across multiple sectors, enabling efficient and effective production processes. Collaborate with IT and Planning departments to create digital versions of production dashboards within the ERP system, providing real-time monitoring of production status, cost, and automatic allocation of resources. Had a significant impact on the success of the organization, both in terms of manufacturing excellence and people skills, driving continuous improvement, and ensuring a safe, efficient, and productive work environment.

Karachi

As a Project Manager, the main responsibilities are to create project schedules, analyze expansion requirements, develop capital expenditure budgets, conduct feasibility studies, and track ongoing projects' progress. Additionally, it involves managing capital-intensive new product development projects and multiple improvement (KAIZEN) projects concurrently.Reviewing and negotiating contracts for products and services from foreign and local suppliers and service providers for outsourced work packages and assignments.Responsible for implementing the self-reliance (Jiritsuka) program of Toyota Corp by monitoring individual training plans for project engineers, resulting in a 30% cap-expense reduction. Engage Toyota Japan and Thailand to source raw material and machines and use them as a point of reference to implement innovative ideas like cellular manufacturing, saving 30% of production floor space in new production lines.Participates in the preparation of a 3-year roadmap for achieving overall department targets (HOSHIN_KANRI) in line with company vision and policy, which facilitates direction setting for preparing annual objectives of Project Management Office. Facilitate on-the-job training in PDCA, Kaizen, A3 business cases, Quality Circle, and 5s methods to enhance project team members' skills from level 2 to level 3 on the Toyota Scale of Jiritsuka.Oversee several key projects i.e; Corolla 2014 project, develop Weld Shop for a new model, including commissioning and pilot production run in line with Toyota Standards Global Body Line project, commissioned a global body line to make three products on a common platform, which is a state-of-the-art technology in the automotive sector of Pakistan. Fortuner 2013 project, designed and developed production facilities for the first locally manufactured SUV in Pakistan, starting from the construction of production facilities, pilot production, to ensure mass production readiness within the timeline.

Pakistan

As a Project Lead, key responsibilities include preparing a project brief that covers the feasibility study, risk register, basic schedule, cost, and other key performance indicators. This project brief needs to be approved by management.Additionally, prepare a project statement of work that includes the complete work scope and get consensus from stakeholders for change management control. Draft a comprehensive project plan that encompasses procurement, cost, quality, and timeline. This plan should also consider the risk of raw material shortage, manpower shortage, and other events that may require a recovery schedule. Monitor and control contractors' work procedures to ensure they comply with the company's health, safety, and environment policies, quality standards, and delivery targets.Source, select, and procure machinery such as welding equipment, pumps for sealant, air compressors, and sample parts from local and global suppliers. Additionally, you will be responsible for preparing and monitoring all required interfaces with other projects, contractors, consultants, and Toyota Japan & Thailand. Participate in quality audits and safety walks to identify quality issues and assess hazards in the manufacturing process. Overall, ensure the project is delivered on time, within budget, and to the required quality standards while also managing risks and ensuring compliance with safety and environmental policies.

Samputprakan,Thailand

TMAP is the R&D center for all the Toyota Affiliates in the Asia Pacific Region responsible for new vehicle development, production operation, quality, and logistics support in the region. My role was to manage the projects in Malaysia, Egypt, and Pakistan with regard to technical support, project engineering, and provision of materials and machines to run mass production. Main responsibility is to collaborate with various departments and affiliates in planning and executing new vehicle development programs, specifically in the scope of Body Assembly Engineering. This involves preparing machine specifications in accordance with Toyota standards, overseeing machine fabrication until final acceptance, and developing a master schedule from project initiation to shipment of machines and materials to the affiliates.Responsible for recommending standardized sourcing and packaging to reduce costs for sheet metal parts, as well as preparing technical process documents necessary for operating the machines in accordance with safety, quality, and productivity standards.Worked on several projects, including overseeing the design, fabrication, and delivery of welding jigs and fixtures within a three-month timeframe for Toyota Malaysia's Camry project. Designed plant layouts for the body shop for Toyota Fortuner projects in Egypt and Pakistan, including blueprints of mechanical structures, piping, and equipment specifications for facilities commissioning.

Karāchi, Sindh, Pakistan

Assist in planning capital investment projects and execute all stages of implementation, including budgeting, defining scope, specifying equipment/process requirements, procurement, installation, commissioning, and handover.Contribute to the development of Standardized Work and participate in Kaizen activities and process improvement studies using the Toyota Production System (TPS)Investigate and analyze quality issues related to welding, sealing, surface finish, and fit, in the body-in-white and general assembly process

Complete final year project as a group leader during the last year of graduation. We were studying energy conservation opportunities in a bar rolling mill of refractories section in People Still Mills , Karachi.In the end, we came up with a design of a recuperator to be installed in the exhaust pit for recovering heat from flue gas leaving the furnace. The project was successfully defended in front of NED University Professors and seasoned professionals. All in all, it was a good exposure to the way things happen in real-life engineering problems .

Ms, Energy Management And Systems Technology, 3 Cgpa

Activities and Societies: Interdepartmental Cricket, organizing annual dinners, debates

Iso 9001:2015 - Lead Auditor, Quality Management

Certification for the authorization of auditing quality management system against ISO 9001:2015 .

Pmp, Project Management, Proficient

Project management professional certification (PMP) from Project Management Institute (USA)

Bachelor Of Engineering - Be, Industrial Engineering