Experience as Production Engineer

• Employer

  Dubai Wire FZE

• From

  05 November 2009

• To

  15 January 2014

• Detail

  • Working as Production Engineer & leading 2 departments (Collating and threading along with Hot Dip galvanized and Electro Galvanized Coating) and Reporting to COO.
  • Astutely leading Manufacturing Unit with 200 workers
  • Production planning & scheduling for Manufacturing and Maintenance of Machines
  • Managing the production of M.S wire drawing process and doing necessary changes if required to feed the next department for smooth and efficient production.
  • Managing the production of Annealing & copper coated wire drawing (0.60 & 0.70mm Dia.) process.
  • Addressing daily production ,maintenance and Quality issues and preparing report to overcome with regular Issues
  • Effectively liaised closely with all departments to fulfill delivery requirement
  • Procuring technical and engineering spares from supplier
  • Planned & introduced efficient production methods to maximize company output and profit
  • Enhanced productivity by organizing resources effectively like machines & workforce availability
  • Created an efficient, flexible start-up and finish time for the production line to increase production time and profits
  • Attending weekly operations meeting with Sr. Management
  • Developing Operators skills and promoting them to higher level
  • Maintaining the efficiency of machines and life of equipment’s
  • Installations of new and old machines if required.
  

Experience as Production & Maintenance Engineer

• Employer

  SASCO Air Conditioning Industry

• From

  15 April 2014

• To

  31 December 2015

• Detail

  • Working as Production and maintenance Engineer and reporting to Operation Manager
  • Managing the production of GI, PI, SS, fire rated and MS duct, duct accessories & air terminal devices, maintenance of all related machines and general maintenance of factory.
  • Leading and managing a team of 150 people including Production foreman & Maintenance technicians to achieve the daily target and smooth running of operation.
  • Planning and executing the production plan and realistic production schedule in the shop floor for the best outcome by using available resources and manpower.
  • Investigation of production and maintenance issues, analyzing root cause and rectifying the problems.
  • Coordinating with Sales, estimation, Planning and logistic team for prioritizing the orders and to deliver orders on time
  • Coordinating with Quality department for improvement and issues and rectifying problems to deliver good quality product
  • Scheduling and executing training program for workers with Safety , Quality , Maintenance and production related issues
  • Planning effective manpower deployment and promoting them to next level for company growth
  • Review monthly and quarterly progress evaluation and act upon to attain the target.
  • Ensuring for the required standard of housekeeping and coordinating with workers.
  • Planning and undertaking scheduled preventive maintenance (Periodic & Autonomous) & responding to breakdowns.
  • Managing Maintenance budget by following preventive maintenance and maintaining spares stock for smooth operation and preparing monthly maintenance and cost report.
  • Developing new tools, fixture and equipment for more productivity.
  • Coordinating with machine suppliers for major breakdowns issues
  • Preparation and submission of technical submittals/prequalification to client/authorities and technical clarification to customer.
  

Experience as Production & Planning Supervisor

• Employer

  Donaldson Middle East Filtration

• From

  08 May 2016

• To

  18 September 2019

• Detail

  • Working as Production & Planning Supervisor and reporting to Plant Manager.
  • Leading and managing a team of 70 peoples including production team leader, foremen, technicians & Operators.
  • Preparing weekly capacity plan, monitoring & executing it to meet customer requirement considering resources like machine, manpower & material.
  • Coordinating with logistics & sales to ensure on time delivery & low finished good inventory, achieved 95% from 80% OTD.
  • Leading and controlling the production in support of the business need in order to achieve plant requirements with respect to safety, quality, delivery, cost and budget.
  • Issue & completion of work orders in oracle and maintaining accurate physical inventory stock level against oracle stock, 98% accuracy achieved as per daily cycle count sheet.
  • Responsible for labor efficiency, EHR & Production output which has been increased from 75% to 95%.
  • Maintaining the safety stock of all the critical local & import raw materials (Media, Chemicals, GI & SST Coil etc.) based on forecast & firm orders to ensure smooth operation and raising purchase request to supply chain if required.
  • Responsible to eliminate bottle necks & process control of production line to ensure high efficiency and low production cost.
  • Trained and promoted helpers, operators & foreman to higher grade by providing suitable training & rotation policy which has provided good workforce flexibility on production floor.
  • Using KANBAN & FIFO technique for all critical in-house made sub-components to ensure efficient operation of assembly line.
  • Preparation & Review of weekly & monthly department performance report based on set KPI's of Safety, Efficiency, on time delivery & Quality, taking necessary actions if required and submitting to management.
  • Creating & maintaining BOM & Routing of all the make products in Oracle, more than 1000 BOM created in ERP system.
  • Responsible to maintain product quality to the level set by the QC department, rejection reduced from 2% to 0.5%.
  • Involved in Total Productive Maintenance (TPM) program to ensure low breakdowns, downtime & healthy condition of all the available machines, monthly downtime is reduces to 30% with help of autonomous and preventive maintenance plan.
  • Helping sales team with lead times & costing and pushing them for new orders based on spare capacity.
  • Helping product development team with production process, product costing & sample in order to develop new products.
  • Responsible of safety requirements in shop floor to ensure safe practices are followed.
  • Performance review of all the sub-ordinates in every 6 months based on attendance, efficiency, quality & flexibility.
  • Conducting monthly GEMBA plant walk with team leader & foreman to find the potential improvements, taking necessary actions and follow-ups until the task is done & maintaining a high standard of hygiene and housekeeping (5S).
  ACHIVEMENTS:-
  • Setup of a single piece flow assembly line is done with the help of Manufacturing Engineering team by considering lean manufacturing principles (Takt time, KAIZAN etc.) which has increased production to double with same manpower and no WIP.
  • Automation of plastic extruder cutting station is done with the help of Manufacturing Engineering team which has reduced manpower, increased efficiency and eliminated WIP.
  • Waste & Cost reduction of raw material reduced by 10% by procuring raw material with correct required size & process control.
  • Production lines efficiency increased and manpower reduced by conducting time study, Process improvement, bottleneck elimination, elimination of unwanted transportation & motion between each process and proper training of operators.