ATHAR ZAMAN

**** **** ********, ***********, ** L5V 2T5

Tel: 289-***-****

Cell: 416-***-**** E-Mail: acqvgy@r.postjobfree.com

PROFILE

Operations Manager implemented Quality Systems with over 24 years of progressive and diversified experience in the American, Japanese and Korean Automotive Assembly, Weld, Paint, Stamping, Supply Chain, Project handling and Quality management environment. Strong working knowledge in manufacturing Quality Assurance, reduction of COPQ and Operations management and plant set up activities from ground-up based on Toyota Production Systems tools and Six-Sigma and Lean principles. I bring to the table a unique set of process focused, strategic Quality management systems skills, which I have successfully transferred to several different industries & disciplines. Developed a continuous improvement minded corporate culture. Education includes a Bachelor of Science in Mechanical Engineering and MBA.

QUALIFICATIONS

Quality and Operations Management

Developed Quality Management System for Fuji / Land Rover acting with additional Portfolio of Quality Manager. 50 Global Suppliers developed on PPAP and APQP Product launches.

Proven Operational Excellence Manager Captured savings over $1.05 Million in 2001 and projected $1.1 Million for 2002 through business process improvements by utilizing Six Sigma and Lean Methodologies

Trained in Toyota Motors Japan for Greenfield Assembly Plant infrastructure, Process Total Quality Control and Operations development, Plant equipment and Machinery selection and procurement inclusive of materials 1990. Trained in KIA Motors South Korea 1995

Participated as Team Leader in New Honda QC Circles World Convention in Japan 1985. Elimination of trouble in Die-Casting Machine achieving $ 0.51 Million saving

Trained in Switzerland, Italy,Germany for Plant Machinery. Attended K 98 Plastic Technology Fair in Germany. 1998

Materials Management

Achieved 42% SCM Product Development in 18 months in automotive body & assembly in line with Land Rover-Ford Motors Brownfield Operations. Achieved $ 100 Million Savings

Developed cross functional sourcing teams producing $5.4 Million savings in material in the first year through implementation of Statistical Process Control and Continual Improvement

Trained Supply Chain Management team, effectively reducing line side stock to less than 5% through development and implementation of Key Operational Metrics

30% Rockwell Business Process Improvement. Led diverse, cross-functional teams for corporate productivity, quality by reducing cost of poor quality(COPQ)

Achieved Car assembly erection and commissioning of Toyota plant with 32% cost effective timely completion for Projects, Products and services budgeted targets

Achieved financial target 25% less than Target budget in erection and commissioning of Car/Truck plant with aggressive recruitment and training of engineering and quality teams for KIA South Korea.

Leadership and Management

At FUJI Japan achieved savings $30 Million spend of mechanical elements (machined parts, fasteners and bearings, castings) to domestic and low cost countries.

Facilitated KAIZEN Events/ KAIZEN activities for Greenfield and Brownfield Operations. 5~50 Quality Circles; 5S Activities and 100~1500 Creative Suggestion Systems. Quality Manager for ISO 9001/ QS 9000 Certification for multiple Corporations

Research Paper presented on Concepts & Tools for Productivity Promotion for Asian Productivity Organization Japan, 1994.

CAREER HISTORY

WORLD COMPETITION CONSULTANTS–Business Turnaround Consultants 2012-2015

Head Of Canadian Operations

Achieved on Projects cost savings, optimized systems and successfully utilized technology and engineering solutions to maximize business. Based on newly acquired Techniques.

ROCKWELL AUTOMATION USA –Allen Bradley Products 2008-2011

Operations Manager

Achieved 100% On Time Delivery while maximizing profit margins through Continuous Improvement Lean methodologies. 94% Throughput of out going quality products by monitoring productivity, Quality, Cost, Cycle time metrics.

Achieved Customer Satisfaction by 100% shipping compliance. Developed yearly departmental operating budgets and $60 Million Annual Operating Plans and 10% reductions in materials and operational expenses.

Facilitated Trained Teams and Developed skill metrics and cross trained 25% for Safety and Health, SOPS, ISO 9001:2008 Quality Standards for Flexible manufacturing. Proactive member of Super users team for SAP modules Production Planning, Shop floor Quality

Achieved 15% Improvement in productivity for electro deposition of paints through process and conveying system redesign

GENERAL MOTORS CORPORATION – Chevy, Pontiac, Monte Carlo, Buick 2007

Production Manager

Supervision of Operations with direction of SPQRCE (Safety, People, Quality, Responsiveness, Cost, Environmental) issues. Implemented COMWIP( 8 Wastes) for New Projects and Products. Engine Assembly and Testing validation

New process setups for manufacturing processes. Visual Cell layout based on Global Lean Management System (GMS). Achievement of production targets; 96% throughput.

100% On Time Delivery of finished products based on JIT and implementing Health and Safety Initiatives

FORD MOTORS CORPORATION – Edge, Lincoln, Free star 2006

Production Manager

Management of SQDCME (Safety, Quality, Delivery, Cost, Environment ) metrics in line with Ford Motor Systems (PDCA, 8D Process, QFD, VA/VE.).

Achievement of production targets. 85% throughput. 09% savings in Forecasted Annual Budgets and cost estimates for processes and materials

Facilitated and Cross trained 50% flex team of Group Leaders and Team Members in line with Ford Motors Quality engineering concepts.

100% On Time Delivery of Engine Assemblies achieved by implementing 6 Sigma for engine parts

LAND ROVER FORD – Range rover, Discovery, Freelander, Defender 2002-2005

General Manager Projects and Quality Assurance

Responsible for global logistics, international trade compliance and strategic SCM project.

Led Global Merger Integration Team for warehouse parts distribution activity.

Developed global suppliers to support sales of $5 billion, resulting in $100 million in savings based on Should Costing.

Supervised Quality Management System development for Receiving materials

Acted as a Change Catalyst for Product Launches through PPAP/ APQP initiatives. Set up the KANBAN System for new materials and product.

FUJI JAPAN – Metal Machining Components 1999-2002

General Manager Operations and Quality

Managed manufacturing and quality of casting, CNC/NC Machining, Stamping of ferrous and non ferrous parts for domestic and export markets.

Supervised new products development processes and supply chain of parts and Business Unit pricing strategies

Led Kaizen activities (Quality Circles, 5S Activities, and Creative Suggestion Systems)/ Project management (Facilitated and Training of cross functional teams for Lean Initiatives).

Led New Plant layout/consolidation based on flexible manufacturing systems and specialized precision parts manufacturing inclusive of paint plant set up for metal painting. 25% enhancement in Productivity achieved by built in quality systems

Developed Quality Management System and as Quality Management Representative implemented ISO–9001/QS 9000 through Lloyd’s Register (England).

KIA MOTORS SOUTH KOREA – Pride, Ceres, Sephia, Sportage 1995-1998

Senior Manager Production Engineering

Development of facilities of all Welding, painting and assembly operations and sheet metal parts manufacturing: Value Stream Mapping; Shop Layouts: Equipment Selection; Set up of Production and Quality processes/ Supply Chain Management, Estimating Material and labor resulting in availability of 30% more space and development of Focused Factory

Led Assembly Plant Engineers to finalize with PPMC all assembly shop materials process flows, KANBAN drop off points. Total Quality Control achieved 50% WIP reduction.

Supervised Assembly Engineers to set up SOP establish cut-off points for obsolescence materials and products

24% savings in Procurement and commissioning of Paint Robotic systems for electro coat. with global suppliers.

TOYOTA MOTORS JAPAN – Corolla, Hilux, Camry, Cuore 1990-1995

Senior Manager Projects and Production

Development of Greenfield facilities of all assembly operation, inclusive of value stream mapping, shop layouts, selection of Assembly and testing equipment, consolidation/ facilitation in line with TOYOTA PRODUCTION SYSTEM.

Proposed and supervised Set of Production processes & Material Handling System including KANBAN, parts flow, drop off point and delivery window for new Assembly plant. Achieved 1.5 Defects Per Unit through implementation of Root cause and corrective action and 5 Whys. Developed Model Visual Factory

Responsible for Recruitment training of Engineers, Group Leaders, Team Leaders, Team members on lines of TOYOTA production system tools (Pull System, JIT, JIDOKA, KANBAN, ANDON, TQC,TQM.)

Achieved 25% cost saving in material process productivity improvement flow through Kaizen activity of elimination of Electro deposition splashes on car body

Honda Motors JAPAN- Honda Automobile Cars and Power Products 1983- 1990

Shop Manager Production

Managed Engine Assembly Shop .Implemented SPC tools..

Supervised functional component shop including manufacturing and quality control.

Oversee die-cast parts manufacture and sheet metal parts painting.

Directed the plastic parts manufacturing through vendors (PPAP/ APQP).

Managed Assembly Shop which includes Quality Control Methods based on Seven SPC Tools, X-R Charts, Histograms, Pareto Charts, Fish Bone analysis.

EDUCATION

MCPM- Masters Certification in Project Management, Schulich School of business, York University, Canada, 2010

MBA - Institute of Business Administration affiliated Wharton School of Economics, USA, 1996

B.Sc. Mechanical Engineering - University of Engineering and Technology, affiliated Maclagan College UK., 1982

PMI- Certified Member Project Management Institute, USA and Certified internal Quality auditor

AR ZAMAN

1386 Quest Circle, Mississauga, ON L5N 8B5

Tel: 905-***-**** Cell: 416-***-**** E-Mail: acqvgy@r.postjobfree.com

PROFILE

Operations Manager implemented Quality Systems with over 24 years of progressive and diversified experience in the American, Japanese and Korean Automotive Assembly, Weld, Paint, Stamping, Supply Chain, Project handling and Quality management environment. Strong working knowledge in manufacturing Quality Assurance, reduction of COPQ and Operations management and plant set up activities from ground-up based on Toyota Production Systems tools and Six-Sigma and Lean principles. I bring to the table a unique set of process focused, strategic Quality management systems skills, which I have successfully transferred to several different industries & disciplines. Developed a continuous improvement minded corporate culture. Education includes a Bachelor of Science in Mechanical Engineering and MBA.

QUALIFICATIONS

Quality and Operations Management

Developed Quality Management System for Fuji / Land Rover acting with additional Portfolio of Quality Manager. 50 Global Suppliers developed on PPAP and APQP Product launches.

Proven Operational Excellence Manager Captured savings over $1.05 Million in 2001 and projected $1.1 Million for 2002 through business process improvements by utilizing Six Sigma and Lean Methodologies

Trained in Toyota Motors Japan for Greenfield Assembly Plant infrastructure, Process Total Quality Control and Operations development, Plant equipment and Machinery selection and procurement inclusive of materials 1990. Trained in KIA Motors South Korea 1995

Participated as Team Leader in New Honda QC Circles World Convention in Japan 1985. Elimination of trouble in Die-Casting Machine achieving $ 0.51 Million saving

Trained in Switzerland, Italy,Germany for Plant Machinery. Attended K 98 Plastic Technology Fair in Germany. 1998

Materials Management

Achieved 42% SCM Product Development in 18 months in automotive body & assembly in line with Land Rover-Ford Motors Brownfield Operations. Achieved $ 100 Million Savings

Developed cross functional sourcing teams producing $5.4 Million savings in material in the first year through implementation of Statistical Process Control and Continual Improvement

Trained Supply Chain Management team, effectively reducing line side stock to less than 5% through development and implementation of Key Operational Metrics

30% Rockwell Business Process Improvement. Led diverse, cross-functional teams for corporate productivity, quality by reducing cost of poor quality(COPQ)

Achieved Car assembly erection and commissioning of Toyota plant with 32% cost effective timely completion for Projects, Products and services budgeted targets

Achieved financial target 25% less than Target budget in erection and commissioning of Car/Truck plant with aggressive recruitment and training of engineering and quality teams for KIA South Korea.

Leadership and Management

At FUJI Japan achieved savings $30 Million spend of mechanical elements (machined parts, fasteners and bearings, castings) to domestic and low cost countries.

Facilitated KAIZEN Events/ KAIZEN activities for Greenfield and Brownfield Operations. 5~50 Quality Circles; 5S Activities and 100~1500 Creative Suggestion Systems. Quality Manager for ISO 9001/ QS 9000 Certification for multiple Corporations

Research Paper presented on Concepts & Tools for Productivity Promotion for Asian Productivity Organization Japan, 1994.

CAREER HISTORY

WORLD COMPETITION CONSULTANTS–Business Turnaround Consultants 2012-2013

Head Of Canadian Operations

Achieved on Projects cost savings, optimized systems and successfully utilized technology and engineering solutions to maximize business. Based on newly acquired Techniques.

ROCKWELL AUTOMATION USA –Allen Bradley Products 2008-2011

Operations Manager

Achieved 100% On Time Delivery while maximizing profit margins through Continuous Improvement Lean methodologies. 94% Throughput of out going quality products by monitoring productivity, Quality, Cost, Cycle time metrics.

Achieved Customer Satisfaction by 100% shipping compliance. Developed yearly departmental operating budgets and $60 Million Annual Operating Plans and 10% reductions in materials and operational expenses.

Facilitated Trained Teams and Developed skill metrics and cross trained 25% for Safety and Health, SOPS, ISO 9001:2008 Quality Standards for Flexible manufacturing. Proactive member of Super users team for SAP modules Production Planning, Shop floor Quality

Achieved 15% Improvement in productivity for electro deposition of paints through process and conveying system redesign

GENERAL MOTORS CORPORATION – Chevy, Pontiac, Monte Carlo, Buick 2007

Production Manager

Supervision of Operations with direction of SPQRCE (Safety, People, Quality, Responsiveness, Cost, Environmental) issues. Implemented COMWIP( 8 Wastes) for New Projects and Products. Engine Assembly and Testing validation

New process setups for manufacturing processes. Visual Cell layout based on Global Lean Management System (GMS). Achievement of production targets; 96% throughput.

100% On Time Delivery of finished products based on JIT and implementing Health and Safety Initiatives

FORD MOTORS CORPORATION – Edge, Lincoln, Free star 2006

Production Manager

Management of SQDCME (Safety, Quality, Delivery, Cost, Environment ) metrics in line with Ford Motor Systems (PDCA, 8D Process, QFD, VA/VE.).

Achievement of production targets. 85% throughput. 09% savings in Forecasted Annual Budgets and cost estimates for processes and materials

Facilitated and Cross trained 50% flex team of Group Leaders and Team Members in line with Ford Motors Quality engineering concepts.

100% On Time Delivery of Engine Assemblies achieved by implementing 6 Sigma for engine parts

LAND ROVER FORD – Range rover, Discovery, Freelander, Defender 2002-2005

General Manager Projects and Quality Assurance

Responsible for global logistics, international trade compliance and strategic SCM project.

Led Global Merger Integration Team for warehouse parts distribution activity.

Developed global suppliers to support sales of $5 billion, resulting in $100 million in savings based on Should Costing.

Supervised Quality Management System development for Receiving materials

Acted as a Change Catalyst for Product Launches through PPAP/ APQP initiatives. Set up the KANBAN System for new materials and product.

FUJI JAPAN – Metal Machining Components 1999-2002

General Manager Operations and Quality

Managed manufacturing and quality of casting, CNC/NC Machining, Stamping of ferrous and non ferrous parts for domestic and export markets.

Supervised new products development processes and supply chain of parts and Business Unit pricing strategies

Led Kaizen activities (Quality Circles, 5S Activities, and Creative Suggestion Systems)/ Project management (Facilitated and Training of cross functional teams for Lean Initiatives).

Led New Plant layout/consolidation based on flexible manufacturing systems and specialized precision parts manufacturing inclusive of paint plant set up for metal painting. 25% enhancement in Productivity achieved by built in quality systems

Developed Quality Management System and as Quality Management Representative implemented ISO–9001/QS 9000 through Lloyd’s Register (England).

KIA MOTORS SOUTH KOREA – Pride, Ceres, Sephia, Sportage 1995-1998

Senior Manager Production Engineering

Development of facilities of all Welding, painting and assembly operations and sheet metal parts manufacturing: Value Stream Mapping; Shop Layouts: Equipment Selection; Set up of Production and Quality processes/ Supply Chain Management, Estimating Material and labor resulting in availability of 30% more space and development of Focused Factory

Led Assembly Plant Engineers to finalize with PPMC all assembly shop materials process flows, KANBAN drop off points. Total Quality Control achieved 50% WIP reduction.

Supervised Assembly Engineers to set up SOP establish cut-off points for obsolescence materials and products

24% savings in Procurement and commissioning of Paint Robotic systems for electro coat. with global suppliers.

TOYOTA MOTORS JAPAN – Corolla, Hilux, Camry, Cuore 1990-1995

Senior Manager Projects and Production

Development of Greenfield facilities of all assembly operation, inclusive of value stream mapping, shop layouts, selection of Assembly and testing equipment, consolidation/ facilitation in line with TOYOTA PRODUCTION SYSTEM.

Proposed and supervised Set of Production processes & Material Handling System including KANBAN, parts flow, drop off point and delivery window for new Assembly plant. Achieved 1.5 Defects Per Unit through implementation of Root cause and corrective action and 5 Whys. Developed Model Visual Factory

Responsible for Recruitment training of Engineers, Group Leaders, Team Leaders, Team members on lines of TOYOTA production system tools (Pull System, JIT, JIDOKA, KANBAN, ANDON, TQC,TQM.)

Achieved 25% cost saving in material process productivity improvement flow through Kaizen activity of elimination of Electro deposition splashes on car body

Honda Motors JAPAN- Honda Automobile Cars and Power Products 1983- 1990

Shop Manager Production

Managed Engine Assembly Shop .Implemented SPC tools..

Supervised functional component shop including manufacturing and quality control.

Oversee die-cast parts manufacture and sheet metal parts painting.

Directed the plastic parts manufacturing through vendors (PPAP/ APQP).

Managed Assembly Shop which includes Quality Control Methods based on Seven SPC Tools, X-R Charts, Histograms, Pareto Charts, Fish Bone analysis.

EDUCATION

MCPM- Masters Certification in Project Management, Schulich School of business, York University, Canada, 2010

MBA - Institute of Business Administration affiliated Wharton School of Economics, USA, 1996

B.Sc. Mechanical Engineering - University of Engineering and Technology, affiliated Maclagan College UK., 1982

PMI- Certified Member Project Management Institute, USA and Certified internal Quality auditor

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