Continuous Improvement Water Treatment

Saif Sultan

Chemical Engineer (FMCG Production/Operations Professional)

+92-331-******* • *************@*****.***

• Address: House # 305, Block C, Canal Road, Jubilee Town, Lahore, Pakistan Education

University of the Punjab Lahore, Punjab

Bachelor of Science in Chemical Engineering CGPA: 3.21 2008-2012 Chenab College Jhang BISE Faisalabad

F.Sc Pre-Engineering Marks: 908/110*-****-****

Chenab College Jhang BISE Faisalabad

Matriculation in Science Marks: 882/105*-****-**** Professional Experience

Achievements

Maintained the Crumb Generation at 1% and achieved the company’s target of ever lowest crumb generation on Biscuit Lines.

Maintained the Line Efficiency at 98% and improving the Biscuit Lines productivity by 10%

Maintained the GE/OEE of Salt Plant at 90%, and reduced the Reel wastage from 3 % to 1%

Got FSMS (ISO 2200), PFA & OHSAS Certifications for Salt Plant

Maintain the OEE of Mespack filling line at above 85% and reduce the wastage to below 3% after carefully analyzing the root causes of breakdowns on filling lines

Got 900 scores in AIB Audits for Aquafina Plant

Successfully reduce Bromate in Drinking Water by carefully analyzing the process

Maintain the Efficiency of the filler at above 80% and got appreciation from top management Successfully worked with the ICE France delegates on the project of membrane changing probing test and improving the product water quality

Successfully run both the PET and Bulk Filler at a time with 10 cubic meter Filler tan Key Projects

PROJECT ECO

Reducing Paper consumption by transforming into Digitization

Printing Cost Reduction

Installation of LED Lights and Fiber Glass sheets to reduce electricity consumption during day time. PROJECT SHINE (PRODUCTIVITY ENHANCEMENT)

ECRS Based Project to change the Line layout

SMED based activities to reduce change-over times

Time & Motion study to reduce Headcount

PROJECT ZEAL

An In-house Automation Project to automate Biscuit feeding into Packaging machines.

Reducing head count, Productivity and Capacity Enhancement, Reducing Minor stoppages and Downtimes.

Saving approx. 10 million per annum in terms of Utilities, Manpower and Enhancements. PROJECT FUSION

An in-house Automation project for creating a Splicer unit for Local Packaging machines.

Improving OEE, reducing downtimes and Productivity enhancement as well as cost effective by re- purposing defunct equipment.

Saving about 3 - 5 million per Machine

Job Roles

English Biscuit Pvt. Ltd. Hattar Haripur KPK

Manufactures of Peek Freans

Production Lead: (April 2019 – Present)

Ensure that the production related activities are being carried out smoothly & enhancing operational efficiencies and reducing the down time

Deals with the problems/hazards facing by the production department.

Monitor the process parameters, to look after the machines OEEs.

Monitor the implementation of personal and food hygiene through effective GMP.

Ensure implementation / follow up of the production planning / scheduling of products.

Efficiently manage KPIs of production (Plant efficiency, Output reliability, Overall equipment effectiveness, productivity, wastages, break downs, yield loss, internal and external quality complains, accidents) in order to achieve the set targets of the department.

Ensure CLTI (Cleaning, Lubrication, and Tightening& Inspection) procedures of process & packing area.

Reduce changeover time through ECRS activity by SMED.

Applies TPM framework, tools and techniques across Production Floor.

Organize and facilitate evaluation sessions with the Production Managers and provide all required data to give insight in progress of implementation and execution of the overall TPM master plan.

Make project budget feasibility, layouts, BOQs, get quotations, do price committees, award contract.

Estimating cost of overall project (Material, Labor, Sub-contracting and Rental Equipment cost etc.) National Foods Limited Gujranwala & Muridkey

Leading Sauces and Recipe Mixes Manufactures

Production Executive: (August 2015 – April 2019)

Production Management

Cascade and execute production plans and adjust operational activities by situation assessment according to available information and resources for optimum production performance

(manpower, material and machine) and production attainment.

Plan, coordinate and follow-up maintenance activities viz. routine, periodic maintenance of Ketchup Section, Recipe Section Water Treatment Section, Cooling Towers and CIP / shutdown activities.

Control cost of production by efficient management of available resources as per standards and safeguarding quality and safety of people and products

Communicate information flows from the management to the Production Floor and vice versa.

Product Manufacture: Deliver as per agreed timetable. Monitor KPIs and take corrective actions in case of deviation. Meet operations targets and department objectives.

Compliance: Manufacture as per established standards. Monitor KPIs, GMP and HACCP standards

To ensure the 100% physical stock taking with the SAP and reconciliation with the stores.

Lines monitoring of GE & OEE values

Erection & Commissioning:

Installation of Stephan Cooking Vessel 1200Kg Capacity and Mespack Packing Line for Sauces.

Installation of Sama and Langen packing machines for Recipe Mixes.

Erection and Commissioning of Water Treatment Plant for Sauces Manufacturing and monitoring the supply of treated water to Process and Utilities Section

Provide all resources (Material, labor, equipment’s) for successful completion of project on time and within budget. HSE & Food Safety:

To make sure the awareness to employees about HSE and maintain the standards of HSE and make sure the execution of ISO 18000 and ISO 22000.

Training and Development:

To ensure skill level of employees towards multi skills and improve the knowledge about defects, safety and environment issues.

Plan & execute training plans for associate/staff with coordination of HR Department.

Organize team building activities to celebrate 3R’s (Respect, Recognition and Reward). Punjab Beverages Co. Pvt Ltd. Faisalabad, Pakistan Shift Engineer: (January 2013 – June 2015)

Production & Maintenance AQUAFINA

Managing whole AQUAFINA section (Water Treatment, filling and Packaging Section) according to Quality & Process Standards of Pepsi Cola International.

Managing and operating whole Water Treatment Process from Raw water to finished product.

To ensure 7 hydro system (Chlorination, Sand Filter, Carbon Filter, 3 Micron, UV, Reverse Osmosis, Ozonation)

Responsible for all the maintenance of Water Treatment Section.

Responsible to give maximum production by keeping quality standards.

Managing all the maintenance of Rinser, Filler, Necksleeve, Shrink Wrapper and Palletizer. Responsible for the sanitation of all water treatment section including cip of turbine, 3-micron filter, UV light, Reverse Osmosis unit, brine tanks, rinser and filler tanks, back washing of sand and carbon filter etc.

Responsible for the external and internal CIP of PET and BULK fillers.

Managing and operating Aquafina Bulk (5 gal) plant from empty bottle inspection, its decapping, washing, filling, capping, sealing, shrinking and palletizing.

Managing and operating Aquafina pet line of 0.5 and 1.5 liter

Managing the raw material and successfully uploading the daily production on SAP Report any abnormality of process equipment.

Calibration tools & equipment.

Preparing reports & maintain records. To inspect & see to it that the workplace in his designated scope of assignment is clean & in hygienic condition.

To conduct regular checks on 1) RO/RO membrane, 2) CIP System & 3) Ozonator - controls, pumps, valves, water lines & tanks condition and to repair or replace parts that are defective. Observe preventive maintenance tasks, schedule and equipment servicing.

To prepare & blend salts in a sanitary way & in accordance to Aquafina document Licenses and Certification

Certified Lean Six Sigma Green Belt (CLSSGB)

HALAL LEAD AUDITOR PS3733

Root Cause Analysis

Productivity Enhancement through time and motion studies

ISO 22000:2018

BSL, ERP and Fire Safety

Hazard Identification and Risk Analysis

Academic Activities

Internships

4 weeks internship in Sitara Peroxide Limited, Faisalabad

6 Weeks Internship in Premier Paper Mills Limited, Sheikhupura Additional

Won Best Play Award at UET Dramatics

Served as Head Organizer at ICET Sports Gala

Served as Chief Proctor Sports at Hostel 8, Punjab University for one year.

Skills: Auto Cad, Microsoft Office, SAP (PP, PM and MM Module End User.

Professional Proficiency in English Language.

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