Responsible for overall plant based functions i.e Production and its planning, R&D, QA/QC, Plant engineering and after sales claim.
Heading staff of 150 employees including AM.Production, AMQC and Supervisors.
Prepare regular reports for owners, formulating and revising costing sheets of different types of batteries based on variation in raw materials price.
Improved battery life by 30% (63 life cycles) by new method development of activated carbon mixing that reduced completely fissure issue.
Designing, Engineering and development of new product with different models according to JIS standards i.e MF, Hybrid and Dry charge battery, its formulation and complete setup installation.
Increased productivity by 11% through process modification
Monitoring and ensuring all In-coming, In-process and Finished products with material testings including Physical, Chemical and Electrical testings.
Increased profit margin in Hybrid and Dry charge ranging from 0.25$ to 0.86$ per battery through grid design, pasting and charging process modification.
Report variation in process controls and finding possible solutions to utilize substandard products.
Product realization, re engineering and redesigning with respect to fulfilling customer requirements.
Reducing battery claim from 1.82 % to 0.41% by root cause analysis of the process defect and ensuring corrective action.
Ensuring process improvements, 5S and Kaizen activities.
Guiding and coaching employees by providing training, career counseling and feedback to achieve high performance.

Head of two departments (Production and Overall Quality control)

Responsibilities (As Production Head)

Accountable for production and on time delivery of different brands of MF, Dry charge and Tubular battery through coordination with supply chain department for timely delivery of materials as per production plan.
Managing a staff of 100 associates including 7 Supervisors to ensure smooth operation according to schedule and to achieve production targets and objectives.
Held daily production meetings with staff to ensure objectives and goals were understood and met.
Saved amount 7,85,964 PKR through process improvisation and recycling techniques
Regularly coordinating with maintenance department to prevent production bottlenecks and implementing preventive, predictive and corrective maintenance to minimize machines downtime.
Managing inventory control by providing analysis of inventory adjustments or revisions, and maintain records of inventory.

Responsibilities (As Quality Control Head)

Managing a Quality control system for lead acid battery manufacturing in the sections including PP injection molding, Acid dilution, Alloy, Grid casting, Pasting, Assembly, Formation, Finishing line & Laboratory.
Supervising a QA Officer and 4 Quality control inspectors for effectively maintaining quality control standards.
Reduced battery complaints from 2% to 0.3% gradually
Assuring Electrical testings of finished battery according to JIS standards.
Accountable for the implementation of Quality Management System (i.e Control Deviation, Market Complaints, Self Inspection, SOP preparation).
Formulating quality control plan, work instructions & check sheets for the acceptance of materials and processes.
Successfully implemented IMS System (QMS and EMS), conducted Re-certification and Surveillance audit twice.
Ensuring quality & performance of the materials procured from vendors by controlling product non conformity and continual improvement.
Organizing and performing QA/QC documentation and functions in preparation for successful ISO 9001:2015 and ISO 14001:2015 certifications.
Performing non-conformance analysis by statistical analysis tools including Pareto Analysis and Fish Bone Diagram etc.
Monitoring product quality target levels to ensure compliance with customer expectations.
Creating Quality Control Procedures that require additional inspection and testing requirements beyond the normal Quality System.

Responsible for implementing Quality Control System to ensure that plate manufacturing processes (Formation, Washing, Drying, Plate Segregation, MC Assembly and Cutting) are complying with defined standards.
Supervising 2 Quality control supervisors and 22 Quality Control Inspectors for timely assurance of standards that are being followed.
Reducing wastage of Positive plate by 18% through charging process modification.
Regularly coordinating with production concerned for process non-compliances.
Assisting MQA in conducting planned QA-Audits for verifying the compliances of define standards resulting to corrective and preventive measures.
Conducting daily GEMBA meeting at shop floor with quality control inspectors.
Enhanced productivity of MC battery by 10% (Reduced plate disconnection issue)
Implementing SPC at each battery manufacturing process to reduce wastages and rejections, improving product quality and monitoring process/machine behavior on continuous basis.
Developing and sharing daily and monthly quality reports with Production concerned.
Ensuring that all chemical testings are being performed as per the defined frequency in Day and Night shifts.
Maintaining master log of process deviations and reports of Non-confirming products for periodic analysis.
Ensuring that all quality procedures are in line with the requirement of Quality Management System (ISO 9001:2015).
Assisting MQA in conducting in-house training of quality control inspectors to improve their skill level on continuous basis.
Verifying and revising Quality standards, Pictorial SOPs as and when needed with the approval of MQA/GMQA.

Supervising 20 Quality Control Inspectors of the sections including Grid Casting, Pasting, Formation and Laboratory for timely assurance of standards.

Checking and reviewing SOPs for Sb % in feeding Lead and Quality of cork Spray.
Reduced complaint of PbCO3 by 31% (Plate drying and washing system modification)
Assurance of temperature settings of GCM furnace and its accessories.
Any modification in the design of existing mould of grids.
Worked as a team member for the implementation of QMS ISO 9001:2008.
Maintaining quality of Lead oxide powder by assuring the standards of Oxidation degree, apparent density and Acid absorption value.
Ensuring quality of pasted panels preventing from any defect.
Reducing the claim of paste shedding and whitish negative plate.
Conducting process audits.
Analyzing chemical and physical properties of formed positive and negative plates from IGO and TDO processes including their controlling parameters such as temperature, moisture, pH, acid specific gravity, current and voltage of circuit.
To carryout chemical analysis of Lead powder, unformed and formed plates and Electrolyte using Titration method.
Managing Inventory of Chemicals and performing instrument calibration.
Reviewing and updating test methods and procedures according to SOPs.
Preparing chemical analysis report on daily basis, sharing analysis results with concerned departments, maintaining all records and update charts/graphs of all testings.
Updating and Maintaining all paperwork related to the analysis (Calibration Log, RM and FG etc), NCR, DCRN, Deviation, CAR, PAR, SOPs, Standards and work instructions.
Developing and maintaining kaizen sheet and working on 5S.

Managing a shift for Sugar production, refining, quality control and losses.
Supervising 50 employees of daily shift in production department.
Improved sugar recovery process by 11% from final molasses
Keeping up to date records and maintain logbook during shift.
Conducting employee performance reviews.
Enhanced quality of R1 grade sugar by 17% (Improved Carbonation system)
Examining machines and instruments up to working standards with coordination of Mechanical, Electrical and Instrumentation departments.
Ensuring availability of process chemicals and their proper usage as specified by SOPs and JSA\'s.
Assessing cleanliness of process house machinery for the avoidance of fermentation or deterioration of sugar by bacteria.
Coordinating with sugar godown officer for the segregation of R1, R2, and R3.

Assisting Shift Chemist for Production processes and Quality control.
Reduced energy cost by 7% (Efficient use of 5th Vapor)
Improved extraction process of sugar from cane by 8%
Preparing MIN through SAP and Oracle.
Supervising Juice Clarification, Carbonation system, Pressure Filtration, and Talo-Clarification work stations.