Production Engineer FMCG, Milling & Operations Optimization

Hanif Zahid

Production Engineer FMCG Manufacturing Commissioning Maintenance & Operations Optimization

+923********* · ****.**********@*****.*** · Karachi, Pakistan · LinkedIn: engrhanifzahid

PROFESSIONAL SUMMARY

Production & Planning Engineer with proven expertise in high-volume flour milling operations, plant commissioning, and industrial project

management. Delivered up to 67,875 MT annual throughput, recovering significant production capacity through downtime reduction and process

optimization. Skilled in PLC-based automation, preventive maintenance, and cross-functional coordination, with experience in shutdown

maintenance and turnaround projects for major industrial facilities. Recognized for a data-driven, results-oriented approach that consistently

improves operational efficiency and reliability.

PROFESSIONAL EXPERIENCE

Ismail Industries Limited - Flour Mill Division, Port Qasim, Karachi

Production Engineer April 2025 - Present

• Directed and monitored 67,875 MT annual production throughput across multi-product flour milling operations (Maida, Atta, Fine Atta, Red Atta,

Suji & Bran).

• Managed plant operations averaging 5,400+ MT monthly output, ensuring adherence to production KPIs and delivery schedules.

• Supervised and analyzed 33,543 breakdown minutes ( 559 hours annually), impacting production continuity.

• Identified and controlled 6,858 MT annual production loss (~10%) through structured downtime monitoring and corrective action

implementation.

• Reduced recurring stoppages and improved startup stabilization time, recovering ~295 MT of additional monthly production capacity.

• Conducted breakdown root cause analysis (RCA) in collaboration with maintenance and electrical teams to enhance equipment reliability.

• Strengthened cross-functional coordination between Production, Maintenance, and Planning to improve plant availability (~90% effective output

efficiency).

• Utilized data tracking and performance monitoring tools to support decision-making and operational reporting.

Unity Foods Limited - Sunridge - 01, Port Qasim, Karachi

Trainee Engineer May 2024- March 2025

• Successfully commissioned a Swiss Buhler Flour Mill Plant (270+130 TPD), ensuring all mechanical components—pumps, conveyors, roller

bodies—were fully operational.

• Conducted IO testing of PLC-controlled equipment and automation sensors, achieving seamless plant operation from day one.

• Minimized downtime by troubleshooting and resolving mechanical issues during commissioning, contributing to uninterrupted production.

• Assisted in planning preventive maintenance and inventory control, supporting continuous operations and reducing potential equipment

failures.

• Monitored daily production activities to ensure adherence to quality standards and optimized line efficiency.

• Coordinated with shift teams to achieve production targets while maintaining high product quality.

• Gained hands-on experience in shift management, line performance analysis, and process documentation, strengthening operational

efficiency.

Descon Engineering Pakistan

Planning Engineer Aug 2022 - Aug 2023

• Maintained project schedules in Primavera P6, contributing to 98% on-time project delivery.

• Optimized manpower and equipment utilization by 10% through strategic resource planning.

• Conducted baseline schedule analysis, preventing potential project delays by ~15%.

• Led coordination meetings with clients and contractors, accelerating decision-making and issue resolution.

• Prepared technical progress reports, enhancing stakeholder communication efficiency by ~20%.

• Coordinated closely with engineering and procurement teams, ensuring seamless alignment between execution and material delivery.

KEY PROJECT EXPERIENCE

Descon Engineering Pakistan — Shutdown Maintenance Assignments

• Engro Polymer & Chemicals Ltd. — Shutdown Maintenance (2022)

• National Refinery Limited (NRL) — Shutdown Maintenance (2023)

• Pakistan Refinery Limited (PRL) — Shutdown Maintenance (2024)

Plant Commissioning – Swiss Bühler Flour Mill (400 TPD & 65 TPD)

• PESA Mill 65 Tpd Ismail Industries Limited - Flour Mill Division, Port Qasim, Karachi – (2025)

• PESA & Roller Mill 130 & 270 Tpd Unity Foods Limited - Sunridge Foods Limited, Port Qasim, Karachi – (2024)

CORE COMPETENCIES

Production & Operations

Production Planning & Scheduling OEE Improvement & Downtime Reduction Process Optimization Commissioning & Startup Operations Root Cause Analysis

Systems & Tools

SAP Production Module Primavera P6 MS Excel (Pivot Tables, VLOOKUP, Dashboards)

Maintenance & Projects

Shutdown & Turnaround Maintenance Mechanical Inspection & Coordination Preventive Maintenance Planning Equipment Reliability Support

Quality & Safety

GMP & Food Safety Compliance Workplace Safety & PPE Compliance Process Documentation & Reporting

EDUCATION

University of Engineering & Technology, Lahore Bachelor of Science in Mechanical Engineering 2017-2021

IBA Public School, Sukkur Intermediate, Matriculation 2012-2016

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