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Manager Plant

Location:
Al-Hasa, Eastern Province, Saudi Arabia
Posted:
January 15, 2020

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Resume:

SAJID ALI

Plant Management Operational Excellence Strategic Planning

Contact: +966*********

E-Mail: adba4f@r.postjobfree.com

Industry Preference: Plastic / Manufacturing /Packaging Location Preference: GCC

Proven track record of participating in high level operational initiatives, including process reengineering & improvements, turnaround management and reorganization

Profile Summary

An Enterprising Leader with 18 years of experience in spearheading plant operations for the setting up of standards for strategic utilization & deployment of available resources to achieve organizational objectives and ensuring the strategic objectives are well understood and executed by the team

Steered the management of Green Field Projects in plastics including Extrusion Blow moulding. Stretch Blow moulding, Sheet Extrsuion, Injection moulding, screen priniting and thermoforming

Played a pivotal role in the implementation of measures that led to cost reduction in Plant by approx SAR 4 Million by implementing lean activities and cost saving initiatives in production, logistics, warehousing and maintenance.

Established long lasting relationships with key accounts and reduced customer complaints by 35% through implementation of proper control systems and robust corrective and preventive action program

Key Resource Planner with hands-on experience in planning for manpower, material & money for successful completion of projects while ensuring regulatory & EHS compliance

Core Competencies

Plant Operational Excellence Project Planning & Execution Cost Reduction Initiatives

Process & Productivity Standardisation Resource Optimisation Continuous Improvement

Value Stream Mapping Client / Stakeholders Engagements Team Building & Leadership

Organisational Experience

Since Mar’16 with Saudi Plastics Packaging Systems (Takween Group, Saudi Arabia) as Plant Manager

Key Result Areas:

Spearheading diverse range of plant activities such as evaluation of strategic plans, capacity planning, process control, cost management & quality assurance to ensure top & bottom line profitability

Managing all technical & managerial aspects including developing reports on performance analysis and planning for better productivity

Innovating quality processes / procedures; creating vision for objective and translating ideas into clear & actionable business requirements & recommendations

Steering the successful roll-out of plant operations; defining scope, setting timelines, analyzing requirements, prioritizing tasks and identifying dependencies as per preset budgets

Directing process manufacturing activities for strategic utilization of available resources & machine loading; preparing work instructions for operations of the unit and maintaining reports for decision-making

Identifying the areas of bottlenecks & breakdown; taking steps to achieve zero accident & customer complaints through the application of troubleshooting tools like root cause analysis

Implementing operational techniques for reduction in cycle time & identification of improvement opportunities and cost reduction measures to achieve substantial reduction in expenditure

Monitoring the performance of the team by establishing a system of reports and communications including reports, cyclical meetings to achieve strategic organizational goals

Highlights:

Achieved

oCost saving of approx: 4 Million Saudi Riyal - highest in the orgnization

o135% of gross profit achieved which was the highest in the organization

oAA+ rating in in BRC – the only plant in GCC to achieve the same

oIntroduction of Bar code for Finished goods in the Plant

Reduced:

oLabour cost per ton by 16% - Utilities Cost per Ton by 19% and Maintenance cost per Ton by 7%

oWarehouse cost by SAR 340,000 by Optimization of space, 5-S implementation, proper inventory control

oLogistics cost by 500,000 by optimizing and value stream mapping of deliveries.

oProcess waste from 1.3% to 0.95%

Successfully optimized manpower through proper planning, value stream mapping, training which reduced manpower from 260 to 223

Led the development of technology based Process and Quality Team through, training and competency based appraisal system and development needs

Previous Work Experience

Oct’13 – Mar’16 with SandS International Plastics, U.A.E as Operations Director

Highlights:

Headed, directed and led sales & operations team by managing 80 members

Implemented cost control measures for success full completion of project within budget

Led the successful setup of Blown film, CI printing press, bag making plant from scratch to start of production involving pre-feasibility study, construction of plant including liaising and maintained relationship with engineering consultants, government bodies, selection and maintained relationship with suppliers

Sep’12 – Sep’13 with Saudi Can Company Ltd. (Haji Abdullah Alireza and Co. Ltd.), Saudi Arabia as Plant Manager – Plastics

Highlights:

36% increase in Total production from 11.5 Million bottles per month to 15.6 Million bottles per month for First half 2013 Vs first half 2012 by participating in value re-engineering and lean implementation activities

Reduced customer rejection by 75% by implementing control systems and robust corrective and preventive action program

Managed

oBRC/IOP certification without any major NCR’s for Blow Moulding Department

oRe-certification of ISO 9001 without any major NCR’s

Implemented preventive maintenance program in line with TPM culture

Organized training sessions for subordinates to improve their skills of which contributed to less number of breakdowns that increased overall production

Established robust quality assurance / control systems from scratch for product and process quality, for manufacturing, purchasing, sales and logistics, and compliance to regulatory / customer requirements

Introduced:

oKaizans culture which created ownership of goals and helped achievement of KPI’s for Shop floor workers

Oct’07 – Aug’12 with Siddco Plastics Industries Ltd. as Sr. Manager Plant and Operations

Highlights:

Established factory from scratch and gained profits within a short time period with optimum utilization of resources being the first person hired by the organization.

Single handedly managed the sales and operations and managed a team of over 200 members

Saved about 200k per annum by participating in value re-engineering and lean implementation activities; combined printing machine and labeling machine to use same manpower for both processes and implementing cell concept system in Injection Moulding Department

Managed the certification of ISO 9001, ISO 14001, OHSAS 18001 systems for the Siddco Group Ltd. at Siddco Plastics, United Oil Supply Co. and Empire Terminals Ltd.

Implemented Oracle based ERP (Cyframe – ERP software for Plastic Industries)

Developed technology based team including Production Manager, Production Supervisors, Process Technicians, Asst. Purchase Manager, Inventory officer, Logistics Executive, Assistant Manager Maintenance, Maintenance Technicians, QA Manager, QA technicians and Line Inspectors to support and sustained manufacturing practices and QMS

May’06 – Oct’07 with Emirates Refining Co. (IFFCO Group, Sharjah, UAE) as Junior Manager Production (Plastics Department)

Highlights:

Managed the ISO 9001:2000 re-certification program in the department

Implement TPM in the department (First in the IFFCO group)

Implemented PAMCO to monitor and improve machine efficiencies

Reduced:

oNumber of Leaky Bottles at ERCO from 3 NCR’s/month to 1 NCR/month

oBreakdowns on ASB stretch blow moulding machines

Developed Process approach culture at all levels in the business with an aim to provide long-term success

Nov’03 – May’06 with United Can Company, Dubai, U.AE. as Production In-charge

Highlights:

Directed a highly motivated team of quality, development and production staff

Feb’02 – Nov’03 with Emirates Polystyrene Industries, Jebel Ali Free Zone, Dubai as Production and Quality Control Supervisor

Highlights:

Got appointed as Packaging Representative in the QC team for driving innovation projects on packaging

Managed Production and Quality Team

Certifications

Certified Internal Auditor for BRC – Global standards for Packaging and Packaging Standards

Certified Six Sigma Green Belt from International Quality Fedration

Certified Internal Auditor for Integrated Management Systme from SGS

Trainings

TPM-Total Productive Maintenance

Plant and Machinery Control

Basic Food Hygiene

Leadership Competency Model

Academic Details

2001: B.E. / B.Tech, in Mechanical Engineering First class 2001 from Mehran University Of Engineering and Technology, Jamshoro, Pakistan

Highlight: Awarded “worthy” by vice chancellor of the University for successfully designing and fabrication of an Industrial Robot for Final Year Project

Personal Details

Date of Birth: 1st July 1976

Languages Known: English, Urdu, Sindhi

Address: P.O.Box 66466, Al Ahsa 31982, Saudi Arabia



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