Inspiring leader, award winning customer service professional and seasoned project manager with more than 9 years of experience of managing large teams, designing and optimising customer centric processes, uplifting sales of current and new products and delivering projects in both private and public sectors.Project Engineer with exceptional credentials managing project scope, cost, and schedule, in a multidisciplined organizational environment, delivering successful industrial projects from developing user requirements, scope definition leading to conceptual design, construction, startup, and turnover. Expert in planning, organizing, and managing resources to successfully complete project goals and objectives, while honoring predetermined constraints.
Quality Management Professional with more than 09 years of experience in Implementation, Training and Auditing of Quality Management System (ISO 9001:2008). Statistical Process Control Techniques, Kaizen, Lean Manufacturing, 5S, Six Sigma Implementation. Working knowledge of various International Standards such as ASME, ASTM, AWS, API, ISO etc.
Production Engineer with expertise in Material Identification/Characterization Techniques, Metrological Inspection, NDT, Coating & Welding Inspection and Mechanical Testing of pressure vessels, mechanical structures, hydraulic systems, engine parts etc. Through knowledge of Machining, Fabrication, and Assembling of ferrous and non-ferrous parts/assys for Aerospace, Automotive, Oil & Gas industries etc. Strong knowledge in Metallurgy and worked on Metal Production Line comprised of crushers, furnaces, grinding Mills, iso-static presses and maintenance of plant equipments. Certified Six Sigma Green Belt, Certified Productivity Specialist.
Project management Vendor Management Production planning
Operations management Analytical skills Quality assurance
Risk management Decision making skills Process Improvement
Performance management Customer Relations Management Supervising operations
Staff Training & Development Assembling equipment Results orientated
Project Manager, National Development Complex (Jan’ 11 - Present)
Responsible to create detailed work plan which identifies and sequence of activities needed to ensure successful completion of the project in time.
Manage the entire product line life cycle from strategic planning to tactical activities.
Plan, execute, and finalize projects within triple constraints of delivering on time, within budget and scope objectives, including acquiring resources and coordinating efforts of team members in order to deliver projects according to plan.
Evaluation, review and selection of technology platforms, services, contract, budget planning, resource planning, stakeholder and vendor management, project execution, communication and monitoring
Determine, arrange and allocate resources (time, money, equipment etc.) required for the project
Manage project staff according to the established policies and practices of the organization
Pioneered innovative team building and cross-functional project management techniques to expedite workflow, simplify processes, and reduce operating costs.
Monitor the progress of the project, make necessary adjustments and comply changes as necessary to ensure the successful completion of the project
Managing and tracking the Design Change and the Request for Information Processes.
Identify, effectively communicate, and resolve project issues and risks. Develop risk mitigation plans. Effectively communicate project status to project stakeholders. Coach, mentor, and motivate team members, influencing them to take positive action and accountability for assigned work.
Developing clear and concise weekly/monthly program management reports detailing program across schedule, budget and technical issues.
Established single point of contact for all program related communications with internal/external stake-holders
Implementing and maintaining weekly program manager meeting, focused on identifying and resolving technical and budget issues that might have a negative impact on the progress.
Monitor cash flow projections and report actual cash flow and variance to senior management on regular basis.
Ensure project deliverables are in time, within budget and at the required level of quality.
Specifying market requirements for current and future products, conducting market research supported by continuous visits to customers and non customers
Selected to analyze, identify, and measure workplace hazards or stressors that caused sickness, impaired health, or resulted in significant discomfort to workers through chemical, physical, ergonomic, or biological exposures
Saved $5 million annually by reducing fixed spending 12% and variable overhead spending 20% through a variety of cost-improvement initiatives through better utilization of resources.
Developed and implemented client service program, which expanded small-to-medium client base 35%
Cut product replacement cost by 45% and increased on-time delivery from 75% to 90% using Kaizen approach to quality issues rooted in manufacturing.
Improved customer service satisfaction 5% annually through supply chain management initiatives, inventory control and flexible manufacturing practices.
Identified and utilized variety of learning materials, resources and technology methods [such as: Internet-learning, library, team learning] to support & improve the instructional environment.
Exceeded plans for growth, achieving revenue of $75 million within two years while maintaining high profitability levels.
Led development of process-control instrument that was completed 15%under budget and generated sales at 07 times higher than projected.
Achieved 20% reduction in development time and 15% reduction in development cost by directing development and implementation of operations improvements and change-management strategy for manufacturing division of the organization.
Production Manager, National Development Complex (Jan 06 – Dec 10)
Planned, organized, supervised and implemented manufacturing procedures in accordance with Quality Assurance Methods, new process technologies, organizational strategies and quarterly/annual budgets.
Develop, implement and maintain Process Plan Sheets (PPS) for manufacturing parts and assemblies define stage wise inspections, critical requirements and key characteristics of the product.
Developed identification and traceability system for each part and assembly from raw material stock to finished qualified product and maintain complete birth history record (Database) by using Microsoft Project and Microsoft Access.
Perform trend analysis to enhance capabilities, improve plans and practices and increase conformance to customer requirements. Develop and track quality data by reviewing historical data for trends and takes preemptive action. Maintains technical library. Lead Improvement teams. Provides Leadership, knowledge and Engagement training to Quality Assurance/Quality Control Leads and Technicians.
Monitor production vs. sales to review production schedule accordingly. Ensure enough replenishment of finished goods supply and maintained healthy inventory level.
Identify, develop and deliver necessary trainings to enhance capabilities while working in QMS environment and maintain record of competency profile of 150 team members.
Develop, implement, communicate and maintain quality plan to bring the company quality systems and policies in compliance with quality system requirements.
Maintain records, developed and implemented a complete system for the identification, Storage, Protection, Retrieval, Retention time and Deposition of records.
Review performance of QMS at planned intervals to ensure its continuing suitability, adequacy, effectiveness and assessing opportunities for improvements/need for changes in QMS. Recommend process modifications and equipment calibrations to enhance operational efficiency of the parts and systems.
Selection, evaluation and re-evaluation of all the suppliers (more than 50) used by the company and maintain record of this assessment.
Review and approve supplier/vendor quality documents, procedures, dossiers and Manufacturer Test Data Reports.
Performs quality audits/inspections of contract operations and subcontractors. Tracks corrective actions taken in response to internal and customer audit findings. Monitors quality deficiencies and coordinates corrective actions.
Periodic but regular assessment of customer satisfaction, identification and implementation of consequent improvements
Identification of activities and responsibilities to respond to actual emergency situations and to mitigate adverse OH&S consequences. Major activities include Emergency preparedness & Response (ERP), Emergency control Centre (ECC), Emergency Control Team (ECT), First Responder Team (FRT), Fire Fighting Team (FFT), Salvage Team (ST), First Aid Team (FAT) etc.
Responsible for the development, organization, communication, promotion and implementation of total quality management culture, statistical process control, 5s program, kaizen improvement process, lean manufacturing and six sigma methodology to control and effectively improve product and service quality by using various quality tools for example, process flow chart, SIPOC diagram, surveys, benchmarking, measurement system analysis (MSA), Gage R & R, process sigma calculations, pareto analysis, scatter plots, regression analysis, cause and effect matrix and diagrams, failure mode and effect analysis.
Developed parallel Assembly production line to increase production by 100%.
Improved manufacturing procedures to produce quality products by saving time and money upto 40%.
Deployment of an organization development plan to support flexible work force to reduce idle time from 35% to 10%.
Implemented program to improve training of skilled personnel in the assembly and repair of ordnance components and equipment. Obtained Headquarters’ goal of 100% trained and certified personnel (improved from 75%) which significantly improved quality.
Researched and recommended specific vendors for improved facilities management, resulting in reduced costs and more efficient operations
Dramatically improved product margins and quality levels by implementing new Design-for-Manufacturing programs.
Created highly effective organizational and filing systems, including quick and thorough indexing, filing and offsite storage, resulting in easy access to critical information and streamlined office functioning.
Shift Engineer, Pakistan Atomic Energy Commission (Jan 04 – Dec 05)
Worked as Production Engineer in Pakistan Atomic Energy Commission (Jan 2004 to Dec 2005) in which I performed my job excellently in production section of process industry, which was involved in extracting pure metals from their ores and then using powder metallurgy techniques in order to get pure metals density to maximum value. My specific responsibilities included:
To run the metal production line efficiently by monitoring, tracking and troubleshooting numerous plant equipments involved in the whole metallurgical process.
To deliver the qualified products in the form of bars, rods and blocks to the end user while following the strict International Quality Certification standards ISO 77.120.
Conduct radiographic, penetrant, ultrasonic, and magnetic particle tests on metal parts to determine if parts meet nondestructive specifications. Reviews test orders to determine type of test requested, test procedures to follow, and part acceptability criteria.
Interpret all WPS, PQR and WPQ per ASME, ASTM, AWS and NDE specifications. Choose the appropriate Welding Procedure Specifications (WPS) and assign welders as per welder qualification records.
Deep draw dies designing, making and then manufacturing high precision engine and pressure vessels qualified parts.
CNC and conventional rolling and spinning of ferrous and non-ferrous alloys sheets to form cylinders, cones and typical shapes.
Characterization of the product as well as incoming new material before and after heat treatment.
Participated in major maintenance of these plants as a team leader successfully twice while working as shift cum maintenance engineer during annual shut down.
MS Office, GPRS, VAS, Siebel
Leadership, analytical, organisational, communication, commercial, networking, presentation skills
A team member, self-motivated, resilient and very quick learner
Educational Qualifications and certification
ASNT Certified Level 2 (UT, PT, RT, MT) Inspector (2013)
Total Quality Management APO, Japan (2012)
Certified Welding Inspector PWI. Pakistan (2012)
Six Sigma Green Belt IQMS, United Kingdom (2011)
Lead Auditor Quality Management System IQMS, United Kingdom (2009)
MSc Engineering in Metallurgy and Materials at University of Engineering & Technology, Lahore, Pakistan (2008)
BSc Engineering (Distinction) in Metallurgy and Materials at University of the Punjab, Lahore, Pakistan (2003)