Experienced Project Manager with a demonstrated history of working in the automotive industry. Skilled in Customer Communication, Profit Optimization, Manufacturing, Lean Manufacturing, and Continuous Improvement. Strong program and project management professional with a Bachelor focused in Industrial Engineering , Masters focused in Energy Planning & a Certified PMP.
<div><p>Prepare engineering specification of input parameters required for design and construction of the plant in accordance with KMC</p>
<p>Plan, monitor and control the progress of construction and design phase in coordination with Arch., Civil, MEP consultants</p>
<p>Negotiate contracts with equipment suppliers, construction companies for the commission phase of the project </p>
<p>Plan and execute pilot production phase for the development of new products of KIA, Peugeot considering SQCD KPIs</p>
<p>Prepare operations strategy incl. manpower recruitment & training plan, line efficiency setting, quality assurance system in order to operate the plant efficiently in line with the lean manufacturing principles.</p>
<p>Devise training plan/content/method for fresh workers to achieve KIA standard of Quality & Productivity benchmarks</p>
<p>Recruit, develop & coach engineers, technicians & workers in accordance with training plan and curriculum</p>
<p>Set goals & evaluate the performance appraisal of management & non-management staff on half-yearly &yearly basis</p>
<p>Manage daily production operations ensuring daily, monthly targets are met keeping the safety, quality & cost KPI</p>
<p>Participate in steering committee for cost-saving initiative, annual budget preparation & lean drive in the company</p>
<p>Collaborate with the maintenance department to keep an uptime of the plant in order to achieve at least 95% availability</p>
<p>Participate in COVID response task force responsible for the implementation of SOP by Government & emergency response planning in case of any unforeseen event to safeguard the health of all the employees</p>
<p>§ Attain NOC of SEPA (Sindh environmental protection agency) for construction phase by providing EIA (Environmental impact assessment) report & coordinating public hearing of EIA</p>
<p>§ Successful construction, commission & trials of the manufacturing plant within 18 months- the shortest lead time (from start of construction until the start of production) in the history of Pakistan Automotive sector till date</p>
<p>§ Save 300 MPKR of Cap Ex. by in-house design & construction of Weld Shop Utilities Production Facilities instead of using foreign engineering support</p>
<p>§ Start mass production within 2 months of the trial stage with 80% fresh workers/technicians/engineers by robust training, recruitment & development strategy to save at least 50% recruitment /retention cost as opposed to hiring experienced people & also help to form a unique working culture</p>
<p>§ Enhance production capacity by 40% using lean practices & skill development as well as plant modification within 6 months of mass production which helped in achieving 8000 vehicle line off in first year of operation</p>
<p>§ Advocate good attendance award for operators which improve punctuality by 20 % within 2 months of the implementation</p>
<p>§ Completed design and commissioning phase along with trial production for launching of 2 new products within 6 months</p>
<p>§ Hire and train 150+ staff incl. Engineer, technicians and new team members to start 2 shift operations successfully with in 3 months of deadline to capture the market share in automobile sector</p></div>
Lead work force of 7 direct & 150 indirect reporters across 7 sections in Production Operations to :
Ensure production schedule is adhered with using optimal resources assignment.
Chalk out strategies to make overall manufacturing system more flexible and leaner.
Implement best practices for improving product quality and up keeping safe production operations
Initiate new projects for plant up gradation or process improvement strategies
Source and procure machines, tools & consumable items in liaison with Purchase division
Negotiate contracts for preventive maintenance of machine & equipments with suppliers
Roll out annual operational & capital expense plan considering future projects & capacity expansion targets
Ensure objectives, roles and responsibilities are clearly communicated to avoid grey areas & to meet deadlines
Reduce manufacturing time by improving existing tools, jigs and fixture in liaison with designers
Improve production dashboards in Epicore ERP for real time monitoring & performance summary reports
Streamline production plan in ERP systems by integrating machine/operator skills using Advance Planning by Capability resulting in automated job assignment & reduction in Planning Manhours
Implement centralized inventory management for consumables in liaison with ERP & Material Planning group in to avoid shortage & keep optimal inventory stock
Reduce 13% rework & scrap annually by introducing several templates and gages for ensuring built-in quality for Press brake operation.
Reduce 30% work in process inventory by implementing stage wise production in fabrication shops
Promoted to manage projects in Body & Stamping Shops with team of 6 players . My responsibilities were to :
Initiate the project with consensus of all stakeholders encompassing business case, investment, milestones, roles & responsibilities and KPI for top management approval.
Prepare fiscal year objective of each project team member built agreement on it & evaluate bi-annually (Management by objective)
Review and approve project management plans like procurement plan, quality management plan, technical document release plan & construction plans.
Oversee planning & monitoring of all project phases ensuring challenges are reported and resolved in timely manner & all relevant standards are adhered with
Implement the contract management system which includes induction, rating & selection of contractors & suppliers for outsourced services & machinery
Develop leadership & technical skills of the team players by overseeing on the job & off the job training(s) as part of Self reliance program (JIRITSUKA) for Toyota Pakistan
Drive and initiate strategic planning for department (HOSHIN) including manpower skills assessment and development along with plans for technology upgrades & business process improvement as a key stake holder
Prepare for and monitor all required interfaces with other projects, contractors, consultants, regulatory bodies & Toyota Motor Co.
Prepare comprehensive Project Plans encompassing procurement, cost, quality & timeline.
Develop recovery schedule if required to accommodate changes and risk of raw material shortage, manpower shortage and other events
Select Source & Procure machinery (welding equipment, Pumps for Sealant, Air Compressors etc.) and sample parts from local & global suppliers
Monitor project progress in terms of cost & time and weekly report key issues
Develop junior staff on Toyota Way of Production & Project Management by on Job training
Design material flow, production layouts & related documents as benchmark for new model trial production & mass production
Corolla 2014 Project(440 MPKR): Design & Installation of 1500 sqm Welding Plant for Corolla 2014 involving MEP works as well as trial production run ensuring compliance with Toyota Standards of Quality & Safety
Global body line project(48 MPKR) : Sourcing & installation of PLC operated global body line for making welded body for 3 products on the same production line (Hilux, D-Cab & Fortuner) which is a state of the art facility in automotive sector of Pakistan
Fortuner 2013 Project (100 MPKR): Lead the introduction of 1st Pakistan manufactured SUV from initiation till handover. Scope included construction of welding plant and trial production run involving fabrication of 30 welding stations & plant construction of 300 sqm.
Reduce 30% (30 MPKR) of Capital Expense on welding equipment for Corolla 2014 by design plant layout to maximize usage of existing facilities for simultaneous production of new & previous model
Reduce 30% foreign engineering support (10 MPKR ) in Corolla Project from Toyota Motor Japan and Thailand by designing Welding Process specifications for the first time in IMC
Lead the shortest product launch in history of IMC by completing project cycle in 10 months for Body Shop Activities
It’s a leadership role in the regional project management team providing engineering support on body making process, project management system to all Toyota Motors Affiliates in Asia Pacific Region
Prepare technical documents necessary for smooth execution of project including Project Plans, Machine specs, manufacturing process specs, plant construction, quality and time standards
Execute functional check for the machines installed to capture punch list & resolve issues in liaison with other divisions
Facilitate make v/s buy decisions for tooling and machines by providing comprehensive technical and commercial reports to management
Lead trial production to ensure all the manufacturing problems in the body making process & quality problems in the product are resolved before mass production
Camry 2012 Jigs: Fabrication and dispatch of 20 Welding Jigs for Toyota Malaysia one week ahead of 3 months schedule
Fortuner Weld Plant Design: Design of Production system for body weld process including design for mechanical structure, piping diagram, production layout & machine specifications for body shop in Egypt & Pakistan within 2 months planned time
Camry 2012 Shell pilot run: Lead trial production of Doors, Hood & Luggage to confirm production quality and process capability before mass production in liaison with Production, Quality & Maintenance Engineers for Toyota Thailand achieving quality and time KPIs
Capacity Up: Reduce takt time for Hilux White Body line from 72 sec to 56 sec in Toyota Thailand Plant
Proposed common material source for SUV & Mini Van sheet metal parts exported to India & Indonesia to reduce tooling cost & inventory cost.
Improved part transfer system b/w work stations as a key activity for cycle time improvement from 72 to 56 seconds in Toyota Banpho Plant(Thailand)
Reduced packing cost by 30% of SUV export parts by designing new packing module for door parts to be combined w
Corolla Hemming Line (120 MPKR) : Source ,procure & commission 2 hemming press , 6 welding jigs ,compressed air & cooling water piping along with electrical jobs for Hood & Luggage Production Facilities from feasibility study to handover stage
Welding process standardization : Prepare process time and material consumption standards for 2 models in Welding shop in order to setup benchmark
Special Purpose line (2 MPKR) : Install production facilities of 1200 sq meter special purpose line to be used for off-line vehicle building for Armed Forces and commercial customer
Reduced operational cost by 50 PKR/unit of Corolla by re-engineering sealant dispensing system through installation of sealant pump instead of cartridges
Installed part transfer conveyor for stamping scrap disposal in Press Shop using local resources saving execution time and capital expense
Designed part transfer system including racks , trolleys and calling system to implement Pull type inventory movement from ware house to shop floor for Corolla Production
Learn Toyota Production System & implement it on Body Shop Floor
Understand Auto Body Manufacturing Process by visiting supplier factories & Work Shops