Shakeel Haider Sheikh

**** *** **** *****, *** # 5, Grand Blanc, MI 48439

Cell #: 810-***-****; E mail: ac2gjs@r.postjobfree.com

Summary of qualifications:

A seasoned graduate engineer with over twenty years of experience in printing and converting flexible packaging industry. Proven track record of leadership, people development and bottom-line results. Strong abilities in team building, achieving business objectives and continuous improvement.

Extensive experience in flexible packaging converting plants includes film extrusion/co-extrusion using PET, OPP, Nylon, LLDPE and other resins. It includes the converting of these various film substrates into bags, pouches and laminated roll stock. I have experience with wide web and narrow web printing using both Flexographic and Rotogravure presses with water-based and solvent-based ink systems. My printing experience includes Pre-Press activities like design development and plate & cylinder manufacturing.

I have worked extensively with the sales and customers for new product development & problem solving from concept to sampling, machine trials and final commercialization.

A team focused Lean manufacturing leader who manages “Manufacturing Teams”, has a strong “P&L understanding” and a history of developing products & people while managing production operations.

Accomplishments:

• Managed a corporate backed $50M capital investment and subsequent $10M equipment investment for new complete converting line, due to business growth.

• Experience with developing Laminated roll stocks, labels, pouches by using wide web printing like Flexographic, Offset, Rotogravure along with all the pre-press and post converting process like Lamination, Pouch Making, Slitting, etc.. The design development & exposure to printing plates & cylinders were also part of my experience. Also, supervised the tissue converting project from launching to commercial production with continuous growth.

• Used cross-functional team concept with bottleneck analysis tools, achieved savings, and increased throughput in the manufacturing system.

• Established & maintained Daily, Weekly & Monthly reporting system.

• Developed the ISO 9000, ISO 22000 system model & got the Certification.

• Developed new business by involving the Sales Team for new customers, both Nationally and Internationally.

• Analyzed the inventory of raw materials, machine parts & production supplies and cut down the dead money by 40% without any operation stoppage or loss to the company.

• Critically reviewed the procurement processes/procedures and implemented changes, resulting in lead time reduction by 20%.

• Managed the development of alternate Sourcing Strategy for many raw materials, machinery and parts including plastic resins, films, Aluminum Foil and hence achieved the price reduction of 10%.

• Team member in start-up of new Division/Business of Flexible Packaging (from scratch)

• Received Certification from ASIAN PRODUCTIVITY ORGANIZATION for “Problem Solving Techniques in Production Management from Japan. Also, Statistical Analysis learning was part of this program.

Skills & expertise:

• Flexographic Printing, Lamination & Converting

• Corrugation & Converting

• Rotogravure Printing, Lamination & Converting

• Flexographic Printing Plates & Cylinders making & mounting

• Blown Film & Co extrusion/ Barrier Films

• Plant Management

• PPC

• Strategic Planning & Visioning

• New Product Development

• Sales & After Sales Services

• P & L Budgetary Management

• Project Management

• Preventive & Predictive maintenance

• New Company Start

Ups

• Capital Equipment Planning

• Tissue Converting

• Lean Manufacturing

• Continuous Improvement

• Procurement Management

• Materials Management

• SAP

• Estimation

• Supply Chain

• Injection Molding

• Quality Assurance

Professional experience:

Kasmy Pack Pvt. Limited, Lahore/Grand Blanc, MI

A family owned company. They have a very ambitious team with hands on experience in Packaging Converting. They are situated in Lahore Pakistan supplying flexible packaging materials to Multinationals & National customers. Have worked with them mostly remotely as well as physically through periodic visits.

Project/Plant Manager January 2016 – June 2017

Plant/Project Manager responsible for overseeing all plant projects and operations

Responsibilities:

• Responsible for the deep collection of data and analysis done with regards to Market trends, Site selection, Selection of Equipment like Printing, Lamination, Slitting machines & decision of Plant layout etc. In other words, I was fully involved for the new company setup from A to Z.

• Led the research work on selection of printing presses & other converting equipment and got the quotations from European machine manufactures including W&H, Bobst, Cerutti, Flexotechnica, Nordmechnica, COMEXI, Titan etc.

• Created a culture committed to employee safety, production and manufacturing safeties along with continuous improvement of plant.

• Completed monthly reports, presentations, and corrective action involving plant performance to budget and other defined KPI's.

• Reduced packaging material costs through utilization of new technology.

• Performed all production planning for facility.

• Narrow down the selection of equipment w.r.t market requirement and finalize equipment after negotiating the best value for money.

• Participated in the selection of best manpower to run the equipment and the company.

• Completed the machine installations for commercial production.

• Developed Procedures & Processes that can safely deliver a quality product on time to our valued customers.

• Develop the performance management system to maximize the operational efficiency.

LallyPak, Hillside, NJ

LallyPak is a leading vertically-integrated manufacturer of value-added flexible packaging products and services. With 35 employees and $25M Sales, LallyPak offers superior quality, fast production turnaround, and a high-level of technical expertise to deliver flexible packaging solutions. They provide their products are printed laminated roll stock, finished stand-up pouches and bags to fit the needs of their customers.

Plant Engineer August 2015 – January 2016

Responsibilities:

• Responsible for complete plant management of whole flexographic printing & converting departments including maintenance.

• Successfully completed the project of erection, commissioning and running of the 10c Uteco Printing machine for commercial production.

• Responsible for the installation of new machines & Implementation of lean techniques.

• Developed and communicated plant mission that included "being the cleanest plant in the industry, embracing continuous improvement, and being committed to a progressive safety culture."

• Direct reports were Assistant Plant Manager, QA Manager, Engineering Manager, Technical Manager, EHS Manager; along with dotted line responsibility for Plant Controller and HR Manager.

• Participated for improvements in process of Flexographic Printing machines (4 Uteco machines) and converting to Bags and Laminates. Also, implemented the quality assurance, continuous Improvement/ lean techniques like reduction of down time, waste, and inventory rationalization.

• Developed annual business plan, plant budget, and led development of KPI and goal setting for each operating sector.

• Instilled a safety culture into a plant that struggled with appropriate training verification and employee accountability.

• Implementation of Regenerative Thermal Oxidizer/ RTO Project to control the polluted exhaust gases/ VOC.

• Implementation of Heat Recovery Project

• Implementation of the project for heating of the Building by utilizing the exhaust heat from RTO through Heat Exchanger.

• Implementation of New Compressor & New Ink Dozing system Project

Meyhoff Leverington Inc. West, Excelsior, MN

(On behalf of Al Ahli Holding Group Dubai, UAE)

Al Ali Plastics packaging is a subsidiary of Al Ahli Holding Group Dubai UAE, a leading packaging and converting company with international foot prints and selling packaging materials like Plastic Bags, Standup Pouch, Zippier Bags & Roll stocks in GCC countries & internationally. The company has sales of $50 M. I had 12 direct reports, 400 non-reports working with 24/6, multi shift operation, with 30 Blown Film Extrusion Lines, 8 Flexographic Printing & 2 Rotogravure Printing Machines and 15 Bag Making & Pouching Machines.

Plant Associate Director November 2011 – May 2014

Responsibilities:

• Associated with Operations, Manufacturing, Sales, Supply chain and other areas within the Company.

• Developed many new customers increasing the sales of 2, 3-layer laminated roll stocks, pouches etc.

• Managed 12 direct reports and 400 hourly non- reports employees in multi shift environment.

• Additional duties performed during the period included, the management of daily business.

• Achieved all business metric targets and lead the process of implementing KPI's in the plant.

• Involved in successfully negotiated contracts with teamsters and active member of labor management committee.

• Implemented a lean focused Quality Management system for on line Quality Assurance, SOPs, Release Norms, Traceability for probing customer complaints and corrective action culture.

• Utilized my Change Management & Turnaround expertise by involving all team members and stakeholders, resulting in turnaround within less than a year.

• Overviewed the gaps in Operations Management, Product Development, Quality Assurance, Procurement/Supply chain, Technology Enhancement, Sales and Customer Services, and implemented the changes required.

• Implemented the preventive & predictive maintenance plans successfully and reduce the down time considerably.

• Oversaw capacity issues and performance improvement opportunities for quantity, and improved throughputs by 20%.

• Introduced the “alternate suppliers” concept. Hence developed the competition and reduced the raw material buying prices by 5-10%.

• Worked with sales team to develop new business, resulting in 120 new customers, both nationally and internationally.

• Introduced the PPC desk with sales forecast culture in the company.

• Initiated the lean manufacturing process, continuous improvement activities like waste reduction, set up time reduction, speed enhancement, and achieved tremendous results.

• Implemented an hourly and monthly team performance metrics.

Adlargroup LLC, Dubai, UAE

Adlargroup LLC is a Consultation company for Packaging industries and solution throughout GCC countries.

Expert Flexible Packaging Consultant March 2010 – November 2011

Responsibilities:

• Worked as Flexible Packaging Consultant for improvements in Operations & Process of Packaging & Converting of Flexographic and Rotogravure Printed Bags, Roll stocks Laminates.

• Provided comprehensive end-to-end management of large format packaging & converting display projects consisting of project estimating, pricing markup/negotiation, quality control specifications, regulatory compliance, product development and testing, assembly instructions, project approvals, resource planning and master scheduling (MRP/ERP), budgeting, purchasing, vendor management, operational analysis with process improvement, stakeholder and conflict management, job costing, shipping schedules and advanced inventory control.

• Managed continuous improvement techniques, for reduction of down time, waste reduction, inventory rationalization.

• Done consultation for Flexible Packaging Films, Flexographic & Rotogravure Printing, Adhesive Lamination, Plastic Co Extrusion & Converting Processes.

Packages Limited, Lahore, PK October 1980 - January 2010

Established in 1956 as a joint venture between the Ali Group of Pakistan & Akerlund & Rausing group of Sweden (now a part of Amcor Europe) Packages Limited is a converter of folding cartons, corrugated boxes and flexible packaging. Additional Information available at www.packages.com.pk. The Ali Group is consisting of 5 Subsidiaries, 4 Joint Ventures, with Flexible Packaging international plants in Pakistan, Sri Lanka & South Africa.

The Flexible Packaging division has Co Extruders, Flexographic & Rotogravure Printing, and state of art Adhesive Laminators & other converting equipment. They serve all MNCs and other national customers. I have worked with 20 Direct reports & 200 Indirect Reports, running 24/6 multi shifts operation. I have worked in the following positions.

Responsibilities:

Plant & Project Manager Supply Chain October 2008 – January 2010

• Responsible for all operational activity related to plant safety, materials/product quality, plant scheduling, production efficiencies, employee development and training, inventory control, waste control, housekeeping, maintenance, facility management and ensure job tickets provide sufficient communication to produce products that meet customer specifications.

• Developed and managed the domestic supply chain of parts, raw materials (Pulps, chemicals etc) for in-house Paper Mills and worked with IFC on recovered fibers Project.

• Managed a healthy competition among Paper Mills Raw material suppliers for price reduction and new sourcing.

Plant Materials Manager - Head of Supply Chain April 2006 – October 2008

• Managed the $150M Procurement Department for the Company, as well as the paper mills.

• Critically reviewed the procurement processes/procedures and implemented the changes, resulting in lead time reduction by 20%.

• Experienced in local and international vendor management/development, procurement (including capital equipment procurement), and contract negotiation.

• Managed the development of alternate Sourcing Strategy for many raw materials, machinery and parts including plastic resins, films, Al Foil and achieved the price reduction of 10%.

• Successfully managed Third Party Logistic services (3PL) for the company, which included local and overseas procurement/imports.

• Negotiated the best value for the company for contract manufacturing and services.

• Negotiated best prices and initiated cost effective projects, which resulted in savings of $15 million. The main materials were Plastic granules for in house Extrusion, white & colored concentrates/Master Batches, Plastic films, all paper mills chemicals, Paper & Board and spare parts, etc.

Plant Stores & Inventory Manager March 2002- April 2006

• Served as Bridge between Sales, Operation and Supply Chain Department for efficient materials management for all the divisions like Paper Mills, all the Business units like Carton line, Shipping container line and Flexible Packaging line.

• Ensured the uninterrupted issuance of raw materials to all the production line including the continuous processes like paper mills.

• Revamped the inventory system as a project and develop cost effective Inventory management of imported as well as local raw materials, machinery and spare parts.

• Reduced the inventory level of Raw Materials by 45% without any stoppage/loss in the company.

• Managed the sales of processed waste worth $5 million.

• Managed the Transportation Department for the efficient operation of the company.

• Developed and managed mini Dry Port for the efficient and economical transportation of all the imported materials for the company. Thereby achieved 30% reduction in transit time and expense.

Plant Production Manager/Plant Manager /Business Unit Manager March 1991 –March 2002

• Successfully established the largest Flexible & Carton packaging unit in Asia, having responsibility for technical evaluation, selection and negotiation, commissioning and production of three 8 Color Wide Web rotogravure and Flexographic printing machines, Co extruders, Laminators, Slitting and Bag Making Machines from Europe, Far East/Taiwan and Canada.

• Developed the lean manufacturing environment with the concept of process & product specifications implementation.

• Implemented an hourly team performance metrics and a new Quality Operating System based on ISO 9000 & SPC & managed out of control production.

• Implemented the Preventive & Predictive maintenance plans successfully and reduce the down time considerably

• For the Project, transferred the Technology, Best practices from “Amcor Packaging Europe” and thus gained System Implementation capability.

• Led the diversified teams 20 direct reports and 200+ hourly team of production planning and general management of flexible packaging operation including after sales services.

• Actively supervised and participated in the preventive and predictive maintenance of the whole plant, which involve ordering of parts, services and interaction with the machine manufactures.

• Worked as a team member with Marketing, Sales, and Customer Services for customer complaints, new business development.

• As a team leader for continuous improvements and development projects, provided the hands-on guidance and assistance to the team members in the various departments.

• Achieved the ISO 9001 Certification for my division and set a benchmark for the rest of the divisions.

Production Planning & Control/ PPC March 1980 - March 1991

• Lead the Production Planning & Control/PPC Department of Flexible, Carton and Shipping Containers Packaging for 12 years.

• Lead the materials management process to meet the optimal inventory level for efficient running of plant.

• Deeply involved in production controls, capacity planning, ordering/addition of new equipment for flexible packaging, as well as Project Leader for lean manufacturing to improve productivity.

• Worked as a team with marketing, sales, and customer services departments for complaint handling, new business development and worked for productivity improvement projects in the field of Flexible Packaging & Carton & Shipping Container Packaging.

• Deeply involved in the price estimation for the new product price quotation.

Education:

• University of Engineering & Technology, Mechanical Engineering, Bachelor Degree, BSME - 1978

• Govt. College of Technology Sialkot, Diploma of Associate Engineering, DOAE - 1973

• Asian Productivity Organization Japan APO, Problem Solving Techniques, Certification - 1988

• Supply Chain Management from ITC, Supply Chain Management, Certification – 2013

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