Production Manager
Resume:
Saman Akbar
Suite # ***,
M*TOA4, ON
Canada
Ph: (1-416*******
Cell: (1-647*******
Email: ************@*****.***
Profile & Objective:
A qualified food technologist, experienced in manufacturing and development of new products, quality control, quality assurance and quality system ( SQF & BRC) and background in plant operation, and supervision of large teams of process and line workers. Also have experience in implementation of Continuous Improvement Projects like 5’ S, 5 Why’s, TPM, Six sigma and Warehouse Operations.
Oct 2014 to Mar2015 : Production Manager
Shearer’s Foods Canada Inc Guelph Ontario
Job Responsibilities:
*Manage 3 production supervisors, and 110 multicultural hourly staff.
* Managed Health & Safety compliance, Instill a sense of urgency around Health & Safety, Increase Health & Safety awareness through involvement on JHSC committee, Report & Investigate Health & Safety issues immediately, and maintain a safe and secure work environment for all employees and conduct Work place inspections and manage corrective actions.
*Work with Production Supervisors to mediate labor issues and address non productive employee behavior through progressive discipline.
*Work with Supervisors to establish performance goals and provide mentorship to supervisors.
* Build a competent team by meeting with employees, communicating performance expectations, monitoring and appraising performance, coaching, training, disciplining and enforcing corporate policies and procedure to all employees and addressing issues that impact productivity and Morale.
*Ensure all Production, Waste and Downtime targets are met.
*Manage production operation, to ensure the safety of products and product made is within the specifications through enforcement of HACCP, SQF systems, SOP, and work with QA manager for any customer complaints and conduct root cause analysis and implement corrective actions.
* Conduct weekly GMP audits with QA Manager and manage corrective actions and make sure that all corrective actions are closed.
* Help Supply Chain to deliver the Production Schedule and improve the order fill rate to make sure deliveries are made on time to the customers.
*Work with Maintenance Supervisor to ensure that operating machinery & equipment running safely and according to specification and also liaise work with Maintenance Dept for any breakdowns and PM’s and root cause analysis.
*Communicate, Track and promote and achieve operational KPI’s to all employees.
*Participate and assist Plant Director in strategic and long term planning. Including budgeting specifically direct labor where the plant labor cost has been reduced to 0.20 $ / Ibs from 0.30$/Ibs.
*Develop Staff schedule with the help of supervisor’s to make sure that lines are staffed with correct number of people for smooth operations of lines.
*Assist the Plant Director as part of Continuous Improvement and implementation of 5S’s program.
January 2009 to June 2014: Production Manager,
Ready Bake Foods c/o George Weston Ltd; Toronto Canada
Job Responsibilities:
*Manage 3 Production supervisors,1Production Supervisor(Responsible for Health and safety, Environmental), 9 Lead hands and 130 multicultural hourly staff.
* Managed Health & Safety compliance, Instill a sense of urgency around Health & Safety, Increase Health & Safety awareness through involvement on committee, Report & Investigate Health & Safety issues immediately, and maintain a safe and secure work environment for all employees. The LTA was reduced from 10 incidents in 2009 to 0 LTA in 2013, because of which the Plant achieve Silver rating for Go for Gold Safety Improvement Program.
* Maintain strong relationship with Union and Union employees to minimize morale issues and grievances with 50 grievances in 2010 to 10 grievances in 2013.
*Work with Production Supervisors to mediate labour issues and address non productive employee behavior through progressive discipline.
* Build a competent team by meeting with employees, communicating performance expectations, monitoring and appraising performance, coaching, training, disciplining, enforcing corporate policies and procedures, monitors employee satisfaction and addressing issues that impact productivity or morale.
*Ensure all Production, Waste and Downtime targets are met. Waste and D/T was reduced from 35 % waste and 30% D/T to 6% and 7% respectively.
*Maintain Production Supervisors’ shift schedules and arrange relief in the event of accident, sickness, vacation to assure the lines are properly and safely managed.
*Manage production operation, including monitoring work, training, coaching supervisory staff in existing & new procedures, conducting monthly supervisors meetings to discuss Waste, Downtime, Quality, Health & safety, Reliability and process improvement, and involve supervisors in process improvement discussion and help supply chain Manager to improve the order fill rate to make sure deliveries are made on time to the customers.
*Track Production Performance, assuring GMP (Good Manufacturing Practices), quality & health and safety. In 2010 the plant successfully achieved the “A” Ratings in BRC audit and in 2013 the plant still maintains the “A” Rating.
*Inspect operating machinery & equipment periodically to insure that it is running safely and according to specification and also liaise work with Maintenance Dept for any breakdowns and PM’s and root cause analysis.
* Develop, track, communicate and report the operational KPI’s. Prepare and report data analysis to contribute in maintaining and developing cost standards
*Participate and assist Plant Manager in strategic and long term planning. Including budgeting specifically direct labor where the plant labor cost has been reduced from 0.95 Cents / Kgs in 2009 to 0.45 Cents / Kgs in 2013.
*Assist the Reliability Manager in Process Improvement Project (Shadow Boards for cleaning tools for each Line, Line Operation Standard Boards for all lines, and Dough trim Rework process on other lines), 5S’s, TPM etc.
Sept 2005 to Nov 2008: Technical Coordinator,
Speed bake c/o George Weston Foods Ltd, Sydney Australia
Job Responsibilities:
*Facilitate and lead regular reviews of all technical specifications, quality control measures, Bill of Materials & documents relating to machinery settings.
* Co-ordinate &/or assist in NPD (New Product Development) projects.
* Facilitate regular internal audits of site, Quality Control check documents and adherence.
* Lead technical projects as identified.
* Train and coach operations personnel in technical areas such as GMP (Good Manufacturing Practices).
* Conduct trials in Test Bakery and on Production Floor as required and report on outcomes.
* Regular liaison with flour mills and other suppliers re: innovation and improvement opportunities.
* Implement sensory evaluation program and incoming material sampling and Finished Products.
*Ensure GMP, HACCP and ISO requirements are adhered to in conjunction with GWF and regulatory policies and procedures.
* Bill of Material Review (BOM’S) Yearly.
*Review of all Manufacturing and Cleaning SOP’S (Standard Operating Procedures) yearly.
*Customer Complaints Management.
Oct 2003 to Dec 2004: Interim Technical Manager,
Speed bake c/o George Weston Foods; Sydney, Australia
Job Responsibilities:
* Investigate customer complaints and provide investigation results to Customer Information Centre and create weekly reports regarding customer complaints for production floor.
* Review QC records for inconsistencies and errors. Initiate provision of collective and preventative actions, if required.
* Daily review certificates of analysis of incoming raw materials.
* Troubleshoot areas of concern relating to quality and food safety;
* Set up weekly team meetings to overcome issues of concern regarding food safety.
* Perform calibration tasks on in-house equipment like scales and thermometers;
* Co-ordinate internal audit program and conduct audits as per schedule;
* Raise, create and close of non conformances reports after putting corrective and preventive actions related to Manufacturing, Quality and any Maintenance Issues.
* Perform line swabbing for microbiological contamination as per schedule.
April 2001 to Oct 2003: Production Supervisor,
Speed bake c/o George Weston Foods Ltd; Sydney, Australia
Job Responsibilities:
*Manage 4 Line operators and 55 multicultural hourly employees.
* Supervise all aspects of production lines from make up to final packaging.
* Ensure safety and hygienic working order of all machines on lines.
* Ensure timely delivery of production plan with focus on highest quality & cost efficiency.
* Ensure production lines supported with adequate supplies and staffing to meet deadlines.
* Ensure product quality and integrity by monitoring and controlling process and packaging parameters.
* Ensure all necessary reporting, documentation completed and reviewed daily for established process and quality parameter.
* Ensure cohesiveness of the team by effective communication, motivation and if necessary utilization of progressive discipline.
* Continuous improvement of safety quality, quality productivity, GMP and flexibility of lines and staff knowledge.
* Ensure employees take ownership of equipment cleaning and preventive maintenance.
*Take necessary measures to preempt customer complaint. Discuss complaints, if any, with staff in weekly toolbox sessions and implement any necessary corrective and preventive actions.
Nov 1996 to April 2001: Baker,
Speed bake c/o George Weston Foods Ltd; Sydney, Australia
Oct 1989 to April 1996: Senior Production Supervisor
English Biscuits Manufacturers Pakistan.
Education:
Completed AIB Baking Science Course in 2002 Correspondence Course through Bread Research Institute Australia in 2002
Master of Science in Applied Chemistry in 1989
(Major Food Science & Technology)
Professional Qualification:
* Four Quadrant Leadership Course.
* Effective Supervision & Team Leadership course through TACK Training.
* Introduction to Return to Work Coordination course through Work Cover NSW.
*OH & S Consultation course through Work Cover NSW.
*Food Safety Quality Assurance Management Course (Part 1) through Advance Food
Safety
* Food Safety Quality Assurance Management Course (Part 11) through Advance Food
Safety
*Internal Food Safety Auditor Training Course through Advance Food Safety.
*Principles and Application of HACCP Course through Advance Food Safety.
Training:
* Completed the BRI Training in Bread Making for Non- Bakers.
* Lock out Tag out Procedure Training through NSCA.
* Safe Handling/Application of Chemicals Training through Jasol.
* TPM3 Awareness In-house Workshop.
* Confined Space Training through Mines Rescue Pty Ltd.
*Senior First Aid Course through Medilife Australia.
*TPM Awareness Workshop through Centre of TPM (Australasia)
*Food Industry Safety Certification Part 1 & Part 2 (Canada)
*AIB Food Plant GMP / Sanitation Workshop (Canada)
*HACCP Training by Guelph Food Technology Centre (Canada)
Assets:
* Strong communications skills and ability to convey information in a clear and concise manner;
* Excellent interpersonal skills, able to relate to people on all levels and across cultural boundaries;
* Effective organization, time management and prioritization with a proven record in the successful production of multiple products and tasks;
* High energy and motivation levels enhanced by a strong work ethic-willing and able to go the extra distance to achieve results;
* Analytical and methodical, a thoughtful and careful decision maker;
* Key focus on the achievement of top quality, plus high productivity and
Minimal wastage;
*Loyal, honest, persistent and determined.
Career Highlights and Awards:
*Successfully implemented the Pre Ops sheets at Shearer’s foods to develop consistency.
*Implemented Oil washout sheets to manage the Oil utilization and variance.
*Successfully bring the Cost of Labor down from 0.90 Cents/Kgs in 2009 to 0.45 Cents/Kgs 2011.
* Assisted the QA department in getting the “A” rating in BRC Audit in 2010 & 2011, 2012 and 2013
*Successfully brought the Waste of the plant down by implementing the rework procedure.
*Successfully completed 2 Weston’s Plants Closures and associated products transfer in 2010 & 2011.
*Successfully Packaging Changeover project in 2008 in Australia.
*Successfully completed Project Simplex, Project Revamp, Pizza Crumb Rework Project, * R/R 9”waste and Cleaning and Sanitation implementation Projects in 2007in Australia.
*Won Weston’s Best Award for Safety Improvements as part of Safety Improvement& Performance Project in 2002 in Australia.
References available upon Request
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