General Manager

29th June 2011 till Date:  Plant General Manager United Detergents (Unilever Pakistan’s Third party)       
Key responsibilities:-

• Plan, organize and direct the manufacturing and maintenance operations which ensure the most effective return on assets.
• Initiate plans and processes which minimize manufacturing costs through effective utilization of manpower, equipment, utilities, materials and capital. Assure attainment of business objectives and productions schedules while insuring product standards that will exceed our customer’s expectations.
• Continually improve safety record by addressing both physical safety issues and employee safety attitude.
• Establish group and individual accountabilities.

• Planning, design and Business development plans.
• Direct overall financial management, planning, systems and controls.
• Human resource activities to include employment, compensation, performance appraisal and succession planning.
• Establish organizational structure and operating system to ensure the achievement of company objectives.
• Playing key role in long term planning, including initiative towards operational excellence.
• Periodically reviewing the company’s strategy to respond changing business.
• Ensure that quality tools and methods are used in managing the business.
• Improving processes, policies and operational systems.

• Optimum utilization of plant equipment, cost optimization, continuous improvement and Effective control of product yield/loss.
• Planning, Coordinating & controlling plant operations to meet sale demand.
• Strict compliance to GMP and food safety practices.

• Strict compliance to safety, Environment, GMP, food safety practices & training/development of Production Employees
• Effective control of product yield and continuous improvement. Control plant operations to meet sale demand.

• Planning, Coordinating & controlling plant operations to meet sale demand.
• Closely coordinate with supply chain, marketing, R&D and quality control for timely manufacturing and delivery of quality products. Coordinating Machine/Line trials for new launches.
• Strict compliance to safety, Environment, GMP & food safety polices/practices.
• Ensuring efficient and optimum utilization of plant equipment and resources (manpower and material).
• Effective control on manufacturing expenses and overheads. Training/development of Production Employees.
• TPM pillar leader - Jishu Hozen (Autonomous Maintenance).
• Unit Safety committee Chairman.

• Achieved Unilever Pakistan’s values award ‘’ Bringing out the best in all of us’’ twice for the contribution to Unilever Pakistan’s growth through TPM (Total Productivity Management) in 2004 and 2005.
• Being pioneer member of operations team during plant fabrication / installation stage, all machines like meat processing line, Dressing packing/processing line, sauces packing/processing line and milk powder processing plant were installed, initial trials/first production was successfully run.
• Enhanced Dressing plant capacity by 32% by applying different TPM (Total Productivity Maintenance) techniques like efficient labour utilization, effective planning and without any additional capital investment in 2005.
• Reduced man hours per ton from 148 to 110.68 in 2004 by applying different process improvement techniques like time & motion study, small group activities, reduction of minor stoppages, elimination of hard to access areas for CLIT (Cleaning, Lubricating, Inspection, Tightening).
• Increased OEE (Overall Equipment Efficiency) form 64% to 87%
• Completed JH (Jishu Hozen) Step-4 in 2003 which was very much appreciated by JIPM (Japan Institute of Plant Maintenance) and Japanese auditors.
• As a JH (Jishu Hozen) pillar leader of TPM contributed to achieve TPM level-1 award for Unilever Bestfoods Pakistan.
• Implemented the requirement of ISO 9001/2000, HACCP, ISO 14000, OHSAS 18001, HACCP and ‘’A’’ rating in UQCSRM (Unilever Quality & Consumer Safety Road Map) in operations and got the company certified for these systems from 3rd party.
• Awarded first position in written test regarding the use of PPE in 2001 during safety awareness week.

• Advanced TPM regional training course in Autonomous Maintenance Step 4-7 Advance TPM in Manila, Philippines
• Production Supervisory Management Program at Bestfoods Bangpoo and Gateway plants - Thailand.
• Five months intensive training in Australia in different fields such as: -
• Dairy technology, Plant management. Quality management, Fermented milk products Concentrated milk & whey products.

• Total Quality Control by Pakistan Industrial Technical Assistance Center, Pakistan in collaboration with Japan International Cooperation Agency, The Govt. of Japan.
• Quality Maintenance and Manufacturing hygiene at Unilever, Raheem Yar Khan, Pakistan.
• Unilever / JIPM TPM instructor course
• Change for life by KZR Associates, Pakistan.
• ISO-9000/14000, SA 8000 by Technocare Private limited, Lahore, Pakistan
• Food Safety Management HACCP System Auditor training course by Moodi International, Lahore, Pakistan
• 5-S House keeping international Standards by Pakistan Institute of Management, Lahore.
• First aid and Cardiopulmonary Resuscitation (CPR) by Center for the improvement of working conditions and environment, Government of Punjab, Pakistan.
• Seven Tools of statistical process control by Pakistan Institute of Quality Control. Lahore.

• Meat processing plant (Autoclave, Mincer, Shredder, Meat Dryer, Meat stabilization tank, Meat centrifuge)
• Fruits and vegetable processing plant (Slicer, abrasive peeler, cutter, dicer, blancher).
• Sauce processing plant (Spice/paste high speed blender, Vacuum kettle/cocker, Holding tank, Sachet filling machines,Bottle filling and capping machine, cooling tunnel).
• Mayonnaise and dressing plant (Egg processing, batch type egg pasteurizer, batch mixers, colloid mill, filling/capping machine, labeler/coder)
• Juice plant – Bottled & Tetra pak (Plate type heat exchanger, bottle washer, rotary bottle filler and capper, Tetra Brik aseptic filling machine).
• Bread manufacturing plant (Screw conveyor sifter, dough mixer, industrial mixers for cakes, industrial oven, bread slicer).
• Dairy processing plant (Plate type pasteurizer/heat exchanger, milk fat separator, Homogenizer, Tubular UHT plant, multiple stage falling film evaporator).
• Noodle processing line (Dough mixer, a set of primary/secondary rollers, cutting head, steamer, deep fat fryer, Futaba Noodle packing machine, Sanko/Hermetic seal flavor sachet packing machines).
• Dry soups/mixes (Vibratory sifters, Hammer mill, pin mill, Agglomerator, artofax mixer, Bartelt soup pouch filling machine)
• Cubes line (Fat extruder, Z-arm mixer, Corazza cube packing machine)
• Dry desserts/energy drink line(Tumbler mixer, Multi-pack, Toyo pack and Topack pouch filling machines, semi automatic box machines, auto-cartoner).
• Paper/Tissue paper line (Paper pulper, Johnson screens, centri cleaners, Head box, Yanki, Re-winder, sheet cutter)
• Non-Soapy Detergent Bar - NSD (Noodler, Plodder, PLC cutter)