Izhar Syed, P.Eng.

*** - **** ******* **,

Mississauga, ON, L4T 4J6, Canada

416-***-****, abz8zx@r.postjobfree.com

Results orientated professional with experience in Plant Operations,

Quality Assurance, Mechanical Engineering, Lean Manufacturing,

Continuous Process Improvement and Project Management.

Professional Experience

. Quality Assurance Manager, Oldcastle BE - CRH, plc., Mississauga, ON

(Sep 2010 - Mar 2013)

CRH is an international leader in building products and materials.

Oldcastle, Inc. is the North American arm of CRH, plc. Oldcastle BE is a

division of Oldcastle Inc. and is the leading supplier of building

products including architectural glass and aluminum glazing systems,

custom-engineered curtain wall and window wall, architectural doors,

windows & storefront systems.

Reporting to the Dir. of Operations, I was responsible for providing

leadership, motivation and direction to the quality assurance department

at OBE Mississauga. My main responsibilities were:

. Safety and Quality - 1st and 2nd priority respectively. Drive and promote

a culture of safety and quality across the plant.

. Manage APQP (Advanced Product Quality Planning) and PPAP (Production Part

Approval Process).

. Investigate NCR's and take timely corrective actions to address the root

cause of the NCR's.

. Improve customer satisfaction index (CSI) by proper management of

internal plant quality as well as supplier quality

. Improve profitability by reducing customer complaints and cost of poor

quality (COPQ).

. Coordinate new product launches including internal shop mockup as well as

product testing and troubleshooting.

. Share best practices internally as well as with other OBE facilities and

promote a culture of employee engagement & ownership.

. Maintain regular and effective communication between various departments

on quality issues including investigating and resolving internal as well

as external customer complaints.

. Manage field/ site services and product performance tests.

. Track supplier performance and develop contingency plans for poor

performing suppliers.

. Drive continuous improvements throughout the value stream using the Plan-

Do-Check-Act (PDCA) process.

. Track and improve COTD (Complete On-Time Delivery).

. Perform regular audits as a member of joint health and safety committee

(JHSC) to ensure compliance to EHS standards.

. Identify training needs and initiate timely training programs to ensure

adherence to quality standards.

. Drive corporate quality initiatives at the plant level and present timely

status reports to the corporate quality group.

. Department Manager (Operations including Best Practices), Kawneer, ALCOA,

Toronto, ON (April 2007 - Feb 2010)

Alcoa is the world leader in the production and management of primary

aluminum, fabricated aluminum, and alumina combined, and has an active

and growing presence in all major aspects of the industry: technology,

mining, refining, smelting, fabricating, and recycling.

Reporting to the Plant Manager/ Dir. of Eastern Canada, I was responsible

for providing leadership, motivation and direction to the department

operations while ensuring a safe work environment and maintaining quality

production with a continuous improvement philosophy. As part of the

management team, my responsibilities & achievements were:

. Planned, organized and directed Engineering and Manufacturing Best

Practices, Extrusion & Fabrication operations to ensure quality

production and the most effective return on assets. Responsible for

operational metrics/ KPI's on EHS, Productivity, Cost, Quality, On-time

delivery, Labor efficiency, Profitability.

. Developed and implemented manufacturing strategies and action plans in a

unionized environment to minimize manufacturing costs through effective

utilization of manpower, equipment, facilities, materials, and capital

and ensured attainment of business objectives that supported ALCOA's

strategic initiatives.

. Ensured accurate forecasting, capacity planning, scheduling, quality

production & on-time delivery to meet and exceed customer expectations &

as a team player coached and motivated employees to promote employee

engagement & ownership.

. Managed and maintained an efficient and timely production schedule within

budgetary constraints at the Toronto plant.

. Attained 26% improvement in operational efficiency by deploying ABS

principles, lean manufacturing, Six Sigma DMAIC methodology and driving

process improvements through the Plan-Do-Check-Act (PDCA) process.

. Rapidly assessed problem areas and instituted effective turnaround plans

resulting in cost reductions, cash flow optimization.

. Captured operations, engineering, manufacturing, quality and process

management best practices from other ALCOA locations and implemented

those best practices at the Kawneer Scarborough plant.

. Improved OEE by boosting production, reducing poor quality and reducing

equipment downtime by scheduling predictive and preventive maintenance

using CMMS (Computerized Maintenance Management System).

. As an internal auditor, ensured compliance to ISO and EHS standards by

conducting regular internal audits.

. Ensured regular and effective communication between various departments

on quality issues, including investigating and resolving internal and

external supplier quality problems.

. Maintained proactive contact and communication with the sales team for

purposes of forecasting, operational capacity and business planning for

the departments.

. Developed and presented efficient quarterly and annual departmental

business plans to the corporate hierarchy.

. Maintained appropriate departmental staff levels as per production

capacity and business needs.

. Responsible for P&L for the Extrusion, Door, Window, Thermal and Curtain

Wall fabrication operations.

. Quality Engineer, Novaquest Inc., Mississauga, ON

(Sep 2005 - April 2007)

Novaquest Inc. is a leading provider of metal finishing services to the

automotive industry.

Reporting to the Corporate Quality Manager, directed and managed quality

assurance and process management of various products and processes at

three different plants in Brampton & Mississauga, ON. As part of the

management team, some of my responsibilities and achievements were as

follows:

. Successfully led and managed APQP (Advanced Product Quality Planning)

and PPAP (Production Part Approval Process).

. Reduced PPM and scrap by deploying TQM and Process Management to

ensure a state of IC&C (In Capable & Control) and drove continuous

process and quality improvements using Six Sigma DMAIC methodology.

. Managed document control and prepared control plans, process flow

diagrams, FMEA, work instructions and ensured compliance to quality

management system TS16949 by conducting regular internal audits as an

internal auditor.

. Improved customer approval rating by investigating & responding to

customer NCR's (Non-conformance Reports) promptly.

. Reduced supplier issues by 70% by developing and maintaining supplier

performance quality information systems, including the development of

key metrics for tracking supplier performance.

. Improved supplier performance by performing risk analysis and

preparing contingency plans for poor performing suppliers and

identified areas for supplier performance improvements, and ensured

supplier compliance to quality standards.

. Ensured regular and effective communications between various

departments on quality issues, including investigating and resolving

internal and external quality issues using 5 why root cause analysis

and 8D problem solving.

. Managed, supervised and coached lab technicians, quality inspectors

and production employees on process management, Six Sigma, cost of

quality (COQ), cause and effect analysis, Gage R&R, DOE, SPC and

Pareto analysis for problem solving.

. Project Manager, Veritec Inc, Mississauga, ON

(On contract from Jan 2005 - August 2005)

Veritec is a leading consulting company in engineering, water and

wastewater management sector.

Reporting to the Principal Engineer successfully directed and managed

engineering, water and wastewater management projects. As part of the

management team, some of my responsibilities and achievements were as

follows:

. Directed and managed multiple projects from inception to completion

and ensured all targets and deadlines were met as per requirements.

Drafted and submitted budget proposals, recommended budget changes

where necessary, determined and assessed need for additional staff

and/or consultants and made the appropriate recruitments if necessary

during project cycle.

. Defined project scope, goals and deliverables that supported business

goals in collaboration with senior management and stakeholders. Built

and developed business relationships vital to the success of the

project. Proactively managed changes in project scope, identified

potential crises, devised contingency plans and ensured project costs

were within allocated budget.

. Coached, motivated and supervised project team members and

contractors, and influenced them to take positive action &

accountability for their assigned work. Analyzed results and addressed

problem areas. Conducted post project reviews to identify successful

and unsuccessful project elements and developed best practices and

tools for future projects.

. Mechanical Engineer, EFTEC NA, Dayton, OH, U.S.

(Feb 2003- July 2004)

EFTEC is a worldwide leading supplier in the areas of bonding, coating,

and sealing including Application Engineering systems for the automotive

industry.

Reporting to the Director of Engineering & Environment, I was part of the

engineering team that was responsible for the efficient functioning of

the plant processes and equipment. Some of my responsibilities and

achievements were as follows:

. Ensured efficient functioning of the plant processes and equipment and

solved complex manufacturing and engineering issues. Key focus was on

reducing equipment downtime and improving OEE, reliability and

operational efficiency.

. Launched new project proposals (RFA) and performed return on

investment (ROI) analysis on CAPEX projects. Analyzed plant equipment

needs and developed value stream maps, process flow diagrams to ensure

optimal performance & workflow.

. Reduced equipment downtime by 40% by implementing predictive and

preventive maintenance based on FMEA (Failure Modes and Effects

Analysis).

. Improved product quality and reduced product costs by working closely

with cross function teams from purchasing, manufacturing, quality,

logistics and outside suppliers. Reduced waste by implementing lean

manufacturing & Six Sigma.

. Performed regular internal audits as an internal auditor to ensure

adherence to EHS & QMS (Quality Management Systems).

. Project Specialist, Aerospace Mechanics Division, UDRI, Dayton, OH, U.S.A

(Jan 2000 - Jan 2003)

UDRI is a world-renowned research and development organization providing

cutting edge research and advanced technologies to the armed services,

research labs, public and private sector companies in the United States.

. Managed R&D projects on the mechanical behavior of Steels, Titanium

alloys, Aluminum alloys, Plastics and Polymers for the automotive &

aerospace industry. Conducted failure analysis to study the dynamic

response of materials under high temperature and high stress - strain

conditions to ascertain their crashworthiness.

. Ensured successful project planning & implementation, data

acquisition, test data analysis and report writing.

. Developed and delivered progress reports, proposals, documentation and

presentations to various clients like Ford, GM, Chrysler, GEAE, Pratt

& Whitney, Honeywell and Alcoa in a timely manner.

Education and Professional Development

. Master of Science in Mechanical Engineering. May 2002

University of Dayton, Dayton, OH, U.S.A

. Bachelor of Science in Mechanical Engineering.

June 1998

Osmania University, Hyderabad, India

. Professional Engineer (P.Eng.) and a member of Professional Engineers

Ontario (PEO).

. Certified Quality Engineer (CQE) and a senior member of ASQ (American

Society for Quality).

. Training and Certification on Quality Management System TS16949.

Dayton, OH

. Training and Certification on ALCOA Health and Safety Management

Systems. Dover, NJ

. JDE, SAP, CMMS, Microsoft Office Suite

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