Manager Quality

Nadeem Tufail Butt

** ********** ***** ** ******* T2Y 3M2, AB. Telephone: 403-***-****

Email:adlu9q@r.postjobfree.com

Summary: 15+ years of experience in building materials, steel manufacturing, agriculture farm equipment and furniture industries at leadership positions such as Production, Technical, Quality (QA/QC), Manufacturing Operations and Assistant plant manager. A visionary, innovative, proactive, and decisive leader, with extensive experience in delivering high impact business, resource management and process improvement strategies, that promote business growth, optimum efficiencies, cost reduction, maximum utilization of all types of assets and staff development.

Career Background: Lead organizations to develop and implement business strategies for long term and short-term goals. Assisted the functional department managers to transform corporate strategies of business growth into yearly tactical operational plans. This experience has helped me to develop a cross-industrial approach to utilize the best practices from multiple industries to optimize output, productivity health & safety and the environment through implementing effective process improvement strategies and foster a culture of collaboration, continuous improvement and customer service excellence to internal and external customers across the value chain of the organization. Mechanically inclined and monitored equipment efficiencies created preventive maintenance and total productive maintenance plans to reduce downtime and realizing long term asset value. Worked with the senior leadership team for strategic projects and new initiatives. Created reports for upper management and provided them with the basis to make effective business decisions.

Core Competencies: As an operational excellence, Lean and continuous improvement expert with a rare and unique blend of qualifications and extensive experience in Modularization Welding, Machining, Ceramics manufacturing and Agri farm equipment. I have been exposed to the organization-wide operations of multiple organizations. During my various roles in quality management, plant management, operations management, and continuous improvement, I have assisted teams to standardized product and process to achieve operational excellence. Excellent experience in building, coaching and leading effective teams.

I have assisted teams in goal setting and implementing their operational objectives and quality standards, with the goal of achieving significantly better product & process. I helped to standardize the quality, optimization of resources utilization, service delivery and initiating the process improvements to achieve efficiencies throughout the organization.

Created awareness and implemented COTD that is every project is completed on time be defect-free and within budget.

Furthermore have excellent experience in implementing safety requirements and have experience in incident investigation and implementing the resulting corrective and preventative actions.

Skills: Over the years I have been able to develop excellent skills of root cause analysis, communications (written, verbal and listening), customer service, Kanban, Toyota Production System, analytic and collaborative leadership skills, advanced expertise in Lean Manufacturing, Six sigma, Safety leadership, cost reduction, team building and leading, Strategic planning, policies & procedures development, systems implementation, and continuous improvement. I am self-motivated having high integrity, well organized, confident, a good coach for the team, innovative, critical thinking, troubleshooting skills and have pleasant interpersonal skills. Excellent experience in problem-solving by using skills of data analysis and identifying areas for improvement. Influencing teams to get desired results. Influential coach and trainer. Able and eager to learn new methods and train teams.

Achievements

Obtained ISO 9001 certification for 2 companies within a short period of one year, which involved developing and implementing the new quality management system. Furthermore, the certification process involved setting up KPIs and training internal auditors.

Lead internal audits as lead auditor and conducting supplier audits. Hence gained valuable experience of organization-wide operations management.

Reduced the total defect rate to 1.8% from 18% at Tarpon, which resulted in annual savings of $0.3 million annually (via reduced rework time and throughput yield). Consequently, Tarpon was highlighted by the CWB auditors as the leading firm boasting such a low defect rate among its peers.

Implemented a system comprising of digital and automated data aggregation, analysis platform at Tarpon. The system collected and aggregated data in real time from production facilities to calculate key metrics of the Quality Management System (QMS) such as defect rate, thus being able to gauge important quality metrics in real time.

Assisted the safety team in numerous environmental initiatives such as controlling air quality in the welding shop by finding solutions and implementing them to control the Manganese content (inheritance of welding operations) in the shop, per the content limit set by OHS.

Reduced quality related customer complaints by 70% by implementing statistical process control, incoming inspection, and training the customer service technicians.

Spearheaded numerous environmental initiatives, including reducing dust levels. Implemented process to reuse the waste heat of the furnaces for drying.

Introduced automation of numerous manufacturing processes, which increased throughput by 10%.

Developed a new product to conserve water.

Prepared the Environmental Management System (EMS) of Saudi Ceramics, which eventually led the company to pursue the ISO 14001 certification.

Projects Experience

Part of the implementation team at Morris industries to implement the business process integrator solution for efficient use of the ERP BAAN.

Successfully completed a lean Manufacturing Project at Tarpon, which was responsible for reducing welding defects. Ultimately, the project was able to reduce defects to 2% from 13%.

Involved in a sophisticated process improvement project for eliminating non-value-added steps and decreased the cycle time of sanitaryware production and sorting by 10%.

Initiated a zero-defect project of lean where staff were trained on root cause analysis and various techniques of problem solving thus reduced defect rate to 5% from 20% in one year.

Managed quality management program of over 250 multi-million-dollar turnkey projects for Oil & Gas, Industrial, Mining and Power generation. A complete list is available when required.

Experience

Manufacturing Operations Manager

Dynasty Furniture Manufacturing, Calgary AB, October 2018 – May 2019

Introduced the concept of design for manufacturability which helped many designs to be produced with reduced cycle time, while maintaining the quality and productivity.

Updated the safety management system and implemented to comply with the current standards.

Implemented the quality KPIs data collection and reported data analysis to all levels of management for improvements and identified areas for re-engineering.

Created a maintenance schedule that helped in reducing the downtime.

Audited the departments for compliance to the management system.

Oversee the manufacturing operations and supply chain from raw material to finished goods.

Assistant Plant Manager

Morris Industries, Yorkton SK, August 2017 – September 2018

Morris is one of the oldest farm equipment manufacturers. Morris Industries is a unionized facility where I gained valuable experience in managing union workforce and contractor services.

Major responsibilities

Trained the department heads to carry out the risk analysis and management, created a risk register to manage risks.

Participated in new product launch carried out studies to streamline the manufacturing with the design of manufacturability concept, helped QA to create SOPs for the manufacturing processes and carried out time studies.

Identified and implemented the essential KPIs, with reporting the results which helped in utilizing the capacity efficiently and effectively.

Assisted the planning department for proper ERP utilization for effective scheduling to maximize efficiency and productivity.

Trained staff on business process integration dashboard which reduced 10% admin time of the supervisors.

Appointed as employer Co-chair for OHC and created a culture of safety at work and foster a culture of worker safety first. Ensured compliance to the internal, external and regulatory requirement of safety and environment. Headed the incident investigation team.

Developed and Implemented a process to increase communication between the functional department which helped in fostering cohesion among teams.

Chief Consultant

A&N Consultants Inc., Calgary AB, November 2016 --

A&N Consultants Inc. aims to help the Welding shops, Steel Fabricators, Manufacturing companies, Services companies and General Contractors with strategic planning, process improvement, auditing, operational excellence, monitor system, project specs compliance, staff development.

We strive to identify the bottleneck, root causes to improve the process inefficiencies, ISO certifications, business processes improvement.

We provide staff training, project QA/QC support, vendor audits, surveillance inspections, expediting, and lean manufacturing support.

Quality Assurance Manager

Saskarc Industries Inc., Oxbow SK, August 2015 – June 2016

Saskarc industries is a leading steel fabricator in the region.

Developed implemented and monitored QMS complying to ISO 9001:2015.

Managed project quality management systems for the projects and ensured compliance with the applicable standards and codes. Created Documentation required by clients and projects.

Implemented quality KPIs. Gathered data and provided data analysis that helped in improving efficiency.

Implemented Lean manufacturing tools and trained staff for lean tools.

Implemented an inventory control system using the KANBAN approach.

Carried out lean projects of 5S and 7 wastes of production, which reduced significant waste. Introduced and initiated lean project of zero defect, with first time right concept.

Trained and lead QMS internal auditors.

Quality Manager

Warwick Structures Group, (Formerly Tarpon Energy Services Ltd.), Calgary, AB

October 2011 – January 2015

Warwick Structures Group is a leading manufacturer of Structures and is among the first 50 best-managed companies in Canada.

Led the quality department to manage the quality management system of over 250 projects created ITPS, initial approval packages, monitored the progression of turnover binders and as built drawings.

Assisted Supply chain to create and maintain approved vendor list and carried out supplier audits.

Developed and implemented a robust quality management system (QMS) to get ISO 9001 registration and achieved the certification. This QMS was a new development hence polices were developed and implemented many processes were created new, created the SOPs and work instructions. Lead the internal audits.

Trained staff for Non-Conformance Report handling and created an NCR team. Implemented process to identify root causes and implemented corrective actions for the product and process.

Developed and implemented a robust continuous improvement plan, trained the staff for auditing, lead the subsequent auditing team.

Implemented data reporting processes and standardize the product and process specifications.

Developed and Implemented a new process of online data collection and inspection that reduced inspection time with the availability of real time data to control and monitor shop efficiency.

Introduced the concept of COTD (complete on time delivery) of the projects.

Managed the budget of the quality department as well as quality related budget of the projects.

Facilitated teambuilding sessions for management and supervisor level teams.

Developed and implemented a Continuous Improvement process and trained staff.

Quality Manager

Saudi Ceramic Company, Riyadh Saudi Arabia, April 2004 – October 2011

Saudi Ceramic Company is a joint-stock company, the largest manufacturer of Tiles, Sanitary wares and Electric Water Heaters in the country.

Helped the HR to hire staff and advised a performance management system that ultimately was the basis for yearly performance-based incentives.

Trained customer service technicians to achieve customer satisfaction.

Created awareness for Six Sigma and Lean Manufacturing.

Created standard operating procedures to improve efficiency and quality of the process and product.

Updated and maintained the existing standard operating procedures.

Created design review process to help evaluate the design including all stakeholders of the process to improve yield and reduce defects.

Created Manual for ISO 14001 and ISO 18001 for integrated management system of ISO 9001, ISO 14001 and ISO 18001.

Managed the Quality control and quality assurance department for day to day operations, of three main products manufactured in seven plants.

Assisted Supply chain to create and maintain approved vendor list and carried out supplier audit.

Proposed, studied and made feasibility for process and production improvement equipment to reduce cost and enhance quality.

Foster a culture of customer satisfaction with the customer-first approach and established internal customer-supplier awareness.

Production Manager

Regal Ceramics Ltd, Gujranwala Pakistan

August 1984-Jan 2004

Regal Ceramics Ltd was established in 1974, one of the leading manufacturers of porcelain tableware and had1300 full-time employees.

Joined as Ceramics engineer with responsibilities of R&D, production planning & control, later promoted to Production Manager with added responsibilities of quality, safety and maintenance.

Lead the expansion project which includes construction of new building, equipment selection and managing the erection and commissioning of new equipment.

Managed the budget of the plant.

Setup material control protocol and had many waste recycling achievements.

Maximized capacity utilization by improving the production processes, machine efficiencies and facility planning for product flow.

Created a process for evaluation and selection of suppliers/vendors.

Studied and implemented energy conservation measures for better use of energy, including waste heat reuse for drying.

Education and Certifications

Standard First Aid &CPR/AED Level C Blended Certificate #101793548 June 2020

Lean Six Sigma Green Belt.

McGill University 2015

OHC Level I & II from SASM Saskatoon SK.

Welding inspector Level 1 Reg # 17245 with W47 and W59 endorsement.

Canadian Welding Bureau.

Leadership in Safety Excellence

Alberta Construction Safety Association 2014.

Certificate of Achievement Operations Management

SAIT, July 2013

Lead Auditor

ICON Real consult, Certificate Number 06-125 2007.

Internal Auditor IRCA Registration # IA 04496. 2006

Al Khureyaf, Riyadh Saudi Arabia, 2006

Certificate Ceramic Development Technology

JICA, Nagoya, Japan 1998

Certificate Ceramics Kilns and Firing Technology

JICA, Nagoya, Japan 1996

L.I. Ceram (A bachelor level degree)

Institute of Ceramics, Stoke on Trent, U.K 1984

Higher National Certificate (HNC)

Staffordshire University, Stoke on Trent UK 1983

Training and workshops

Sigma Nest Training for using Nesting software for Laser Cutting machines.

ISO 9001 awareness training.

Kaizen Training with studying the Toyota Production System in Toyota Plant in Nagoya Japan.

Gemba Kaizen workshops for process improvement.

Kaizen 5S Workshop.

Six Sigma Awareness workshop.

Management development workshops.

Behavior and communication awareness workshops.

Ergonomics Training.

Contact this candidate