Customer Service Maintenance

RAFIUDDIN

Mobile:

India: +919*********

E-Mail: d04g6g@r.postjobfree.com, d04g6g@r.postjobfree.com,

SENIOR MANAGEMENT PROFESSIONAL

Plant Operations ~ Production ~ Quality ~ Maintenance Operations ~ Strategy Planning ~ Project Management ~ Sales & Marketing ~ Planning & Coordination and Finance.

– Chronicle of success in driving growth across parameters such as Production Planning & Management, Maintenances Quality, Time/ Cost Reduction & Resource Optimisation.

– Excellent leader with solid contributions in mentoring professionals.

PROFESSIONAL OVERVIEW

A seasoned professional all-rounder basically an engineer with 27 years of rich experience in managing Plastics Plant Operations, Manufacturing / Production Management, Electrical, electronic/Mechanical Maintenance & Planning, Project Management, Sales & Marketing , Planning & Coordination and finance. in industry. Presently working as Group General Manager with Blow Group of Industries, Ghana, West Africa. having production capacity 2700 tons per month, around 40 expatriates and 1500 local staff adept at the production of Injection & Blow Moulding, shopping bags, flexible packaging, PET preform, bottle and Jar, HDPE/PP woven Sacks, Thermo forming and trimming, plastics recycling, monolayer and multilayer plant, Flexographic and rotogravure printing, water bottling in the plant. Adroit at carrying complete responsibility of the unit encompassing Production, electrical/mechanical/electronic Maintenance, Quality, Manpower Planning, raw material Management, vendor development, cost reduction, Process improvement, Training and development, product development, shop floor administration, energy audit and conservation, procurement of raw material around the world and spares, purchase of machine, all project work, modification and expansion, finance, technologies and Human resources, business policies, legal formalities & their compliances. .

ORGANIZATIONAL EXPERIENCE

Tenure Designation Company:

Jan 09 Sept. 11 Group General Manager Blow Group Of Industries Ghana (West Africa)

Responsibility: Complete responsibility of the unit

encompassing Production, electrical/mechanical/electronic

Maintenance, Quality, Manpower Planning, raw material

Management, vendor development, cost reduction,

Process improvement, Training and development,

product development, shop floor administration

Sales & Marketing, Planning & Coordination and

Finance.

Manufacturer: injection & blow moulding,

Shopping bags, HDPE/PP woven Sacks, Thermo Forming

Polystyrene food boxes, PET preform and bottles, water

Bottling, plastics recycling etc.

Apr’01-Dec08 General Manager Saafa Plastics Ltd., Tanzania (East Africa)

Manufacturer: injection & blow moulding, shopping

Bags, HDPE/PP woven sacks, pen, strapping tape

PET preform bottles and Jar etc.

Responsibility: Production management, elect/mech

PLC maintenance/project management, Sales & Marketing,

Planning & Coordination and Finance.

Sep’87-Mar’01 Works Manager A.V. Thomas Group of Companies, India (solvent extraction

Plastics, PET preform and bottles etc.)

Responsibility: Production Management electrical/Mech

Maintenance & planning project Management, legal

Formalities and their compliances, Sales & Marketing,

Planning & Coordination and Finance.

Feb’87-Sep’87 Maintenance Engineer Dalmia Plastic Pvt. Ltd., India (HDPE/PP woven sacks)

Responsibility: electrical/mechanical maintenance Project

Mar’86-Jan’87 Shift In charge Swen Plastic Company Ltd., India (HDPE/PP woven sacks)

Responsibility: production/Maintenance

Apr’84-Feb’86 Shift In charge Raj Pipes Pvt Ltd., India (PVC rigid pipes and fittings)

Presently working with Blow Group of Industries adapted at the production of injection and blow moulding plant, shopping bags, PET preform and blow moulding, thermoforming, HDPE/PP woven sacks, water bottling, plastics recycling. The main duty assigned are Production Planning, Manpower & Raw Material Planning, procurement of raw material, vendor development for maintenance activates, purchase of machine and spares, Sales & Marketing, Planning & Coordination and Finance, legal formalities compliances.

.

Group detail

1. Blowplast Industries limited, product shopping bags capacity 1000 tonnes per month.

2. Blow Pak Industries limited, product disposable food and packaging product, injection moulding product, PET preform and bottle, capacity 1000 tonnes per month

3. Blow Sacks industries limited, product PP woven sacks capacity 400 tons per month

4. Blowplast. Recycle industries limited, product plastics waste recycling, capacity. 300 tonnes per month.

5. Blow Chem. Industries limited, product drinking water bottling plant, capacity, 10,000 BPM.

CURRENT JOB PROFILE

To maintain all quality aspects, specification of the products as per customer’s specification.

Reporting to the Managing Director with a prime focus on the profitability, achievements and growth of the group

Managing MIS, P&L & Costing department to reduce production cost by implementing different solutions to improving the productivity. And reducing other costs like electricity, materials cost and minimize other wastages.

Handling all departments and achieving the monthly targets of all departments and monitoring the material resource requirements to maintain low inventory to ensure low cost operations

To maintain good productivity & to achieve the given target for a month.

To prepare required documents, production reports, ISO, Documentation etc.

To prepare shades & solve printing/lamination/ slitting/ pouching in less time when required.

To carry out preventive maintenance of machines and its allied parts etc.

To allocate workloads among the fellow supervisors/ operators/ workers.

To look after the issue & return of Raw materials from RMS as and when required.

To look after the purchase/ procurement/out sourcing of raw materials, engineering goods, work orders as well as dispatches, preparation of packing lists, invoices, and finished product reports etc.

To conduct trials on new development on various machines, develop new vendors and to conduct

Training programmers to new comers etc.

To attend customer complaints and to provide technical assistance and service.

To complete the all project from designing, machine ordering installation commissioning up to the production stage.

To monitor good and proper housekeeping and to take precautions to avoid any human injury.

Key Deliverables:

Production Planning

Scheduling for the planning for overall Production / Stock / Logistics activities, implementing effective techniques to bring efficiency in operations, improve quality standards & achieve cost savings.

Determining the future needs and production capacity for producing required quantities of equipments on pre-defined standards within financial costs.

Overseeing production related tasks including planning, control and trouble shooting for the machineries and equipments for assembly & testing.

Executing Cost control activities such as mass production inventory control, Process control, Product control, statistical quality control value Analysis, recycling and scrap recovery

Supervising customer schedules, capacity planning and releasing delivery plan to over seas, domestic and replacement market customers.

Coordinating with Product development, Process engineering & Quality engineering team for development of new products.

Keeping Inventory under control and monitoring the non moving /slow moving and achieve corporate results (components and finished products).

Knowledge of ERP.

Operations & Maintenance

Implementing TPM activities, plans & schedules for maintenance, operations and annual turnarounds with focus on optimum utilization of manpower, machines & material.

Managing the functions of troubleshooting and preventive / breakdown maintenance of various machines.

Applying TBM schedules & executing productive maintenance.

Overseeing the coordination and maintenance on the ISO /TS 16949 Activities.

Rendering guidance to the small group activities in solving the quality problem and establishing Kaizens for continual improvement.

Responsible for the maintenance of PLC system Design of Electrical panels, dc control panels, frequency Control drive, hydraulic and pneumatic controls, and generator Maintenance, Instrumentation.

Installation & commissioning boilers, generators, chillers, Compressor, Cooling tower & HT/LT substation.

Sound knowledge of electricity act and rules shall be able to coordinate with state electricity board and other related authority for day to day work and for new electrical expansion/up gradation.

liaisoning with the officials of various departments like State Pollution Control Board, Factory inspector, explosive, boiler inspector, electrical inspector, weights and measure, etc

Thorough knowledge of mechanical, electrical, civil and related equipment and working knowledge of all other plant, equipment and utilities.

Sound knowledge of coal, oil, fired water and fire tube boiler, water softener, RO Plant etc.

Quality Assurance & Control

Handling Quality tests and validation of process to ensure completion of projects with in stipulated time / cost parameters, determining the effectiveness of equipments & Machineries.

Taking stringent quality measures including preparation / maintenance of necessary documents & conducting audits to ensure compliance.

Facilitating new product development initiatives with Key focus on QCD (Quality, Cost & Delivery).

Analyzing the data using statistical quality software.

Managing the assembling & testing of manufactured equipments, ensuring adherence to the pre-set technical specifications.

Modification and new machine purchase, etc.

Developing and implementing system and procedure for Material accounting flow of cost security and material audit implementing effective inventory control.

Developing /implementing quality system, standard and procedure Minimum rejection and customer complaints.

Vendor development in production and maintenance activities.

Manpower Planning:

Handling training in various fields such as production, Quality, Documentation, save working method and Environment, good house Keeping etc.

Managing a team of more than 1000 members.

Encouraging the all department employees to participate in inter cross section completion to identify the level of their knowledge.

Identifying the right people for the right position and providing right type of training to increase their knowledge.

Encouraged self-development and training programs as deemed necessary to elevate level of competence and job performance.

Managing large skilled and unskilled manpower and ensuring their motivation/ development.

Upgrading the production facilities/ establishing new facilities if required for specific projects.

Notable Highlights:

Provide executive management, leadership in a medium to large sized manufacturing industry to lead Business operations as profit centre head utilizing proven expertise in production techniques in plastics.

Enable an organization to improve its performance, develop positive direction and realize its potential by building relationships with employees and customers.

Starting up new ventures, turn key projects and/or re-organizing and restructuring sick industries.

Global vendor development experience, strong negotiation skills, and proven cost reduction and profitability management ability.

Installed waste water treatment plant for plastics recycling plant and increased capacity upto 30%.

Cost control and cost analysis

Negotiation and execution of business alliance.

Layout, planning, erection and commissioning of manufacturing units.

Quality Control and product development knowledge.

Strong tool design and development skills and experienced in new product development.

Strong processing knowledge of plastic processing like Injection molding, Blow molding, Roto molding, Tubing, Pipe extrusion and Pet molding.

Searched many supplier of raw material machine and spares around the world while working in Tanzania

and minimised input cost for their all industries

Installed and commissioned oil and coal fired water and fire tube boilers, water softener, Ro plant, Generators, cooling towers, power factor correction panel, distribution panels, HT/LT substation, cable laying, transformer etc.

Designed and made control panels for different plant.

works related to Electrical Permissions, Clearances, Approvals

liaising with the officials of various departments like State Pollution Control Board, Factory inspector, explosive, boiler inspector, electrical inspector, weights and measure, etc

Visited China, Hong Kong, Kenya, Singapore, and Malaysia for raw material and machine purchase purpose.

Worked with Omega, Huarong, Nanrong, ABS, FongKee, Ardor, Chenhsong, Chern horng, Jonwai, Parker, Suyash Pet, Hagihara, Windsor, Hengli, fordah, Starlinger, Hemingston, Hyplas, Ding Kueen, Sunwell, Queens, ASB, AF. AtlasCopco, Kiaser compressors, Kohli, Polygraph, Sunwel, Chumpower and many other machines.

Achievements

Restructuring the entire plastic subs in terms of manpower, technological upgrade, implement right process

in the Organization.

Finalise the Plant Layout based on Lean Management System with objectives as follows:

-Reduction in throughput time, cycle time or lead time

-Reduction in the cost of space, inventory & capital equipment.

-Increase in capacity utilization

Develop a Technical Financial Budget for Machines & Ancillaries

Job Profile & Role Clarity of all the Expatriates

Develop & Implement Kaizen & TQM

Handling of all 5 plants marketing, logistics, operations finance etc.

Successfully identified the root cause of the production loss and increased the tonnage of monthly

production

Implemented Performance Management System in all group companies and helped them to evaluate

managers, engineers, supervisors, and other staffs performance scientifically and in professional manner to

appreciate the intelligent employees of the company.

Capably restructured customer service department & improved the level of service delivery to 90% which

resulted in getting 5% more business from the present customers in terms of new products development

and additional sales.

Successfully negotiated with union to send some of the old employees to VRS without affecting the

operations, which resulted in reduction of the permanent employee cost. Also arranged for a contract labor

for some of the operations which reduced fixed cost drastically.

Revised and successfully implemented the recruitment policy to develop strong middle management team

of Local people

Managed customer services, material planning, Inventory control, Engineering, Human Resources, Quality

control and production.

Resourcefully increased the 20% efficiency of production machines and attained all targets within schedule.

Reduced set up time in three companies by nearly 70% by using QCO (Quick change over methodology)

which resulted in reducing the mould loading time from 8 hours to 3 hours and colour changing time from

2 hours to 35 min.

Changed low morale team into highly motivated team through continually monitored training programs

which helped to reduce the frequent replacement of the expatriate manpower.

Capably developed new vendors in China, South Africa, Korea, Germany, India, Italy, Japan, Belgium,

Spain, Dubai, Austria, Turkey, France, Malaysia, Singapore and Taiwan for pail moulds, plastic processing

machines, utilities and pet mineral bottle production.

Proactively operated to develop and launch new plastic products to specifically meet customers'

requirements.

Project Management.

Managing projects to design and manufacture plastic products for client specific requirements.

Upgrading the production facilities/ establishing new facilities if required for specific projects.

Identifying and developing high quality vendors globally and negotiating rate contracts.

Preparing the plans and budgets to manage the manufacturing operations as a profit centre Managing

projects to design and manufacture plastic products for client specific requirements

Implementation of preventive maintenance plan and Production Schedule for Injection and Blow moulding

machines, pet blow moulding & auxiliary machines to reduce the maintenance cost

Handling all departments and achieving the monthly targets of all departments

Planning the material resource requirements to maintain low inventory and ensure low cost operations

Business Development and Marketing

Negotiating with major multinational and corporate companies to get long term contracts for plastic

packaging units

Developing partnership agreements with leading retail outlets to get major volume sales

Formulating the pricing programmes to increase gross profits

Coordinating all aspects of fast track product launch

Project managed introduction of new products and new product concepts to all major clients and agents.

Handling the customer service department to improve the level of service delivery to highest level

Developing the volume and profitability of overseas market sectors through more effective sales and

marketing campaigns

Projects Completed:

1. 500 TPM capacity shopping bags plant.

2. 600 TPM capacity injection and blow moulding plant.

3. 100 TPM capacity PET preform and blow plant for Jar and bottles.

4. 400 TPM capacity PP woven sacks plant.

5. Multilayer and monolayer film plant.

6. 200 TPM Thermoforming and trimming plant.

7. Rotogravure and flexo-printing plant.

8. 300 TPM Plastics recycling plant.

9. 10000 BPH Water bottling plant.

10. Water treatment plant.

11. Utilities like centralise system of high and low pressure compressor, chillers, cooling tower, dryer, de-humidifier, boiler, generator etc.

ACADEMIC CREDENTIALS

Electrical Engineering from Maharashtra India in 1983.

IT SKILLS

PC proficient since 1988, MIS reporting, Windows XP, Windows Vista, Windows 7, Internet, E-mail, Computer Formatting, Proficient with the use of AutoCAD, MS Office

• Worked with Microsoft Visio, MS Project, Solomon ERP system and Tally.

TRAINING ATTENDED

Operation and Maintenance of Caterpillar Generator set.

PLC system and controls used in process and machine

Electrical safety in solvent extraction Plant.

Industrial safety program in the industries.

Industrial Management and Labour Law.

Pollution control and disposal of industrial Hazardous Waste.

Energy audit and conservation in industries.

PERSONAL DETAILS

Date of Birth : 6th January 1963

Language Known : English, Hindi, Urdu & Marathi, Kiswahili (all speaking, reading and writing)

Permanent Address : Flat No. 611, Utkarsh Nirman, Mangalwari Bazar, Sadar, Nagpur, Maharashtra (India)

Passport No : H8319231 valid up to 31/12/2019

Present Address : same as above.

Family detail : children two 20 and 17 years old.

References

S#

Person Name

Country Designation Company Contact Ph # Email-Id

1 Mr. V.Ravi Kumar India Director AV. Thomas Groups of Companies +919********* d04g6g@r.postjobfree.com

2

Mr. P.K. Modi India VP SURYA AGRO +918********* d04g6g@r.postjobfree.com

3

Salim Turky Tanzania

Zanzibar MD ZAINAB BOTTLES +255*********

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