AKBAR KHAN

Lake Worth, FL *****

610-***-****

ac7ywo@r.postjobfree.com

www.linkedin.com/in/akbarkhan

PLANT MANAGER CONTINUOUS IMPROVEMENT OPERATIONS LEADER

Plant productivity Cost reduction Headcount rightsizing– Improve On time & In Full Delivery

Plant Manager and change leader who uses Lean Six Sigma, process improvement, operational excellence and visual management to increase profitability and sales.Expert in root cause analysis to identify short term corrective action and implement long term preventive action. Servant leader who incorporates respect for humanity to transform behavior and align business and financial objectives in both unionized and non-unionized companies. Bilingual: English and Spanish. Expertise in:

AOP P&L Responsibility

Global Diversity Spanish

Startup & Re-engineer

Lean Mfg Six Sigma

Standard Work SOPs

TPM KPIs 6S OTIF

Coach &Mentor

Gemba Walk

Inventory Control

PROFESSIONAL EXPERIENCE

SERTA SIMMONS BEDDING, Riviera Beach, FL 01/2018 – 08/2018

Largest manufacturer and distributor of mattresses and bedding in NA, employing 6K, 10K+ storefronts and a network of 39 manufacturing facilities.

Kaizen Promotion Officer

Promoted KAIZEN and strategized humane and political savvy way to reengineer auto line and achievethe revisedbudget. Coached 250 colleagues to become quality champions by challenging status quo.

Reduced cost per unit (CPU) by 62% after re-engineering remaining 2 lines. Reduced headcount by 44% by performing comprehensive skills assessment and then selecting most suitable candidates. Introduced daily Gemba walk with visual display of Quality Cost Delivery Morale Safety KPIs to drivecompliance.

Developed Pareto analysis toengage focus on vital few problems with uptime increase from 48% to 75%.

Built quality into product at each station yielding 22% reduction in defective products plant wide.

INTERCOS USA, Congers, NY 11/2016 – 09/2017

Manufacturer of cosmetics through 13 Sales Offices and 11 production facilities in 9 countries.

Continuous Improvement(CI) Manager

Developed CI strategy plant wide for 60 robotized/automated pieces of machinery. Implemented achieving competitive excellence by promoting rapid response to resolve operational problems.

Reduced customer complaints index to 55% from 82% by introducing six sigma philosophy.Increased plant efficiency to 68% from 45% by implementing Overall Equipment Effectiveness (OEE).

Utilized the 8 Discipline approach, A3 Thinking methodology& DMAIC to problem solving to encourage effective rapid response concomitant with enhanced teamwork and building empowered teams.

Used standard work and statistical process control to improve bulk blending, powder compoundingand lipstick manufacturing. Reduced overall material wastage by 24%.

BIOCHEM MANUFACTURING, Jupiter, FL 09/2013 – 10/2016

Manufacturer of Agricultural Chemicals.

Plant Operations Manager

Managed manufacturing operations by applying Lean Six Sigma (LSS) techniques to all 4departments.

Increased plant capacity by 17% after reducing cycle time by 40%. OTIF improved to 98.5% from 69%, head count reduced by 30% and product returns were less than 3% from the prior 10%.

Utilized Design of Experiments to deliver d99 < 40 microns as demanded by aerial spraying operation.

TURNAROUND MANAGEMENT CONSULTANT, Lake Worth, FL 12/2011 – 08/2013

Developed business plan to construct and operate 5 carbonated lines in Africa over 5-month period.

Oversaw ISO 9000 certification for major beverage plant in Trinidad & Tobago over 30 months.

Turned around $100Mbeverage facility in USA by focusing on cost reduction and challenging status quo over 2-year period, thereby preventing company from filing bankruptcy.

COCA COLA ENTERPRISES(CCE), Hollywood, FL 02/2010 – 11/2011

Global manufacturer of carbonated beverages, fruit juices and water.

Maintenance Manager

Maintained the entire plant, utilities, buildings and transport vehicles. Conceptualized project engineering and coordinated project management. Prepared and executed annual operating of $80M. Supervised 32 employees. Executed operational excellence projects. Complied with all federal, state, county, and company’s regulations.

Implemented SAP PM and Total Productive Maintenance [TPM] achieving >95% uptime and increased production by 25%.

Executed 3 Operational excellence (OE) projects and spare parts inventory reduced by 40% to $1.3M.

Led operations team to gain CCE’s certification for General Food Safety [GFS] encompassing ISO 22000, PAS 220, Environment ISO 14001 and OSHA 18001.

MICHIGAN BOTTLING AND CUSTOM PACK, Detroit, MI 01/2007 – 02/2010

Manufacturer of beverages.

Plant Operations Manager

Designed, constructed, recruitedand trained75 employees, complying with all Federal, State, County and Company’sregulations. Prepared and managed annual operating budget of $55M.

Coached all employees in implementing Six Sigma quality principles, 6S and eliminating waste.

PEPSI AMERICAS CARIBBEAN REGION, Puerto Rico 09/2002 – 11/2006

Plant Operations Manager(PR) & Regional Director of Engineering

Administered full P&L and B/S responsibility for PR plant and functioned as Director of Engineering for the 4 plants.

Reduced change over time in PR from 10 to 2 minutes.Reduced Head count and manufacturing expenses by 20% in PR.

Created cross-functional teams in PR and thus raised plant efficiency from to 62% & OTIF to 85%.

Averted Nassau plant shut down by turningaround quality index from Red to Green in 6 months using Six Sigma principles. Increased production by focusing on standard work and process flow.

Won the annual regional Pepsi Blue Quality award for increasing overall quality in the Caribbean Region.

ADDITIONAL RELEVANT EXPERIENCE

TOYOTA TRINIDAD ASSEMBLY, Plant Manager Kaizen – $300MM 500 employees

HEINEKEN INTERNATIONAL BREWERY, Chief Engineer – $100MM 200 employees milling grains into liquid stream

EDUCATION / CERTIFICATION

Master of Business Administration (MBA), University of Warwickshire,UK

Master of Information Science (MS), Penn State University, PA

Bachelor of Science (BSc), Mechanical Engineering, University of the West Indiesaccredited by London University

Bachelor of Science (BSc), Chemical Engineering, University of the West Indies accredited by London University

Lean Six Sigma Black Belt, Villanova University, PA

Toyota Quality & Production Management System

OSHA General Maintenance

Hazard Analysis and Critical Control Program (HACCP) Plant Sanitation

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