Manager Quality

ATHAR ZAMAN

**** ***** ******, ***********, ** L*N 8B5

Tel: 905-***-**** Cell: 416-***-**** E-Mail: **************@*****.***

PROFILE

Quality Systems and Operations Manager 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 based 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 Assembly Plant infrastructure, Process Total

Quality Control and Operations development, Plant equipment and Machinery selection 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 M/C

Trained in Switzerland, Italy, Germany for Plant Machinery, Process Quality Standards

(injection, blow molding, extruders). 1998-9. Attended K 98 Plastic Technology International

Fair in Germany. 1998

Materials Management

Achieved 42% part deletion/Supply Chain Management in 18 months in automotive body &

assembly parts in line with Land Rover-Ford Motors Lean manufacturing concepts.

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

Business Process Improvement. Led diverse, cross-functional teams in the fulfillment

of corporate productivity, quality and bottom-line objectives 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 its initial budget in erection and commissioning

of Car/Truck plant with aggressive recruitment and training of engineering and quality teams

for KIA manufacturing systems in Seoul, South Korea.

Leadership and Management

Led Production Engineering and Quality Control departments for r esource and out-

source projects for approximately $30 Million spend of mechanical elements (machined parts,

fasteners and bearings, castings) to domestic and low cost countries.

Facilitated KAIZEN Events and improved upon production targets; KAIZEN

activities. 5~50 Quality Circles; 5S Activities and 100~1500 Creative Suggestion Systems.

Quality Manager for ISO 9001/ QS 9000 Certification for multiple Corporations

ATHAR ZAMAN 2

Research Paper presented on Concepts & Tools for Productivity Promotion for

Asian Productivity Organization Japan, 1994.

Facilitated Mentored and Coached teams on Automotive Structures, Chassis, Trim,

Painting Engine systems Testing and Trouble Shooting at Honda, Toyota, KIA, Land Rover

CAREER HISTORY

ROCKWELL AUTOMATION –Allen Bradley Products 2008-2011

Production 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 operational expenses. Estimated and Monitored all internal and external customer quotes

Facilitated Trained Teams and Developed skill metrics and cross trained 25% for

Safety and Health, Standard Operating Procedures and ISO 9001:2008 Quality Standards for

Flexible manufacturing. Proactive member of Super users implementation 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, support of workgroup leaders and base operators with

direction of SPQRCE (Safety, People, Quality, Responsiveness, Cost, Environmental) issues.

Implemented COMWIP(8 Non Value added Wastes) for New Projects and Products

Introduction

New process setups for manufacturing processes. Visual Cell layout based on Global

Lean Management System (GMS). Achievement of production targets; 96% throughput.

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, PFMEA etc.).

Achievement of production targets. 85% throughput. 09% savings in Forecasted

Annual Budgets and cost estimates

Facilitated and Cross trained 50% flex team of Group Leaders and Team Members in

line with Ford Motors Quality engineering concepts.

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 and set up activity.

Developed global network to support sales of $ 5 billion, resulting in $100 million in

savings based on Should Costing.

Supervised Quality Management System development for incoming and out going

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

ATHAR ZAMAN 3

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 – 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 inclusive of: Value Stream Mapping; Shop Layouts: Equipment

Finalization & Selection; Set up of Production and Quality processes/ Supply Chain

Management, Estimating Material and labour 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% work in process stock

reduction.

Supervised Assembly Engineers to set up a formal procedure to establish cut-off points for

obsolescence materials and products

Installation and commissioning of Paint Robotic systems for electro coat. Procurement of paint

accessories and material through negotiating contracts with global suppliers.

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

Senior Manager Projects and Production

Development of facilities of all assembly operation, inclusive of value stream mapping, shop

layouts, selection of Assembly and testing equipment, consolidation/ facilitation of Production

Planning and Quality Control in line with TOYOTA PRODUCTION SYSTEM.

Developed and monitored Projects and Products costing aligned with TOYOTA Cost

Reduction Principle

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- 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).

ATHAR ZAMAN 4

Managed Assembly Shop which includes Quality Control Methods based on

Seven SPC Tools, X-R Charts, Histograms, Pareto Charts, Fish Bone analysis.

Accomplished and improved upon: production targets; Kaizen activities;

Quality Circles; 5S Activities; and Creative Suggestion Systems.

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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