SAJID ALI

Plant Management Operational Excellence Strategic Planning

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

E-Mail: adqa4o@r.postjobfree.com

Industry Preference: Manufacturing 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 For Siddco Plastics and Sands International from Pre-fasiblity level to Start of Operations.

Played a pivotal role in the implementation of measures that led to cost reduction in Plant by approx SAR 7 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

o Highest Cost saving among 4 Plants (approx. 7 Million) o 105% of gross profit vs budget 2021

o OEE improvement of 5% 2021 Vs 2020

o AA+ rating in BRC (Year 2017)– the only plant in GCC to achieve the AA+ in BRC o AA rating in BRC (Year 2021) – Only Plant with AA rating in the group o Introduction of Bar code for Finished goods in the Plant Reduced:

o Labour cost per ton by 18% - Utilities Cost per Ton by 19% and Maintenance cost per Ton by 7% o Warehouse cost by SAR 340,000 by Optimization of space, 5-S implementation, proper inventory control o Logistics cost by 500,000 by optimizing and value stream mapping of deliveries. o Process waste from 1.3% to 0.95% (2018 vs 2019) – 0.95% to 0.79% (2019 vs 2020) and from 0.79% to 074%

(2020 vs 2021)

Successfully optimized manpower through proper planning, value stream mapping, training which reduced manpower from 260 to 229 while added extra machines. (2019 vs 2021) 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

o BRC/IOP certification without any major NCR’s for Blow Moulding Department o Re-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:

o Kaizans 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 Started TPM in the department being Team leader for the project in Department Implemented OEE to monitor and improve machine efficiencies Reduced:

o Number of Leaky Bottles at ERCO from 3 NCR’s/month to 1 NCR/month o Breakdowns on ASB stretch blow moulding machines Nov’03 – May’06 with United Can Company, Dubai, U.AE. as Production Supervisor Highlights:

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

Key Account Management

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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