Muhammad Ahsan Sami

Project Management: Spearheaded a 2M+ USD Greenfield Factory by taking charge of core tasks like

• Site Selection
• Preparation of factory layouts for civil design.
• Equipment/machinery selection and procurement.
• Budgeting and scheduling of the construction phase.
• Utilities Planning, piping diagrams
• Erection and commissioning

Odoo ERP Implementation:

• Implemented Manufacturing, Quality and Inventory Modules of Odoo v.14 and conducted end user trainings.

Factory Operations: Led a dynamic team of 15 direct reportees and 50+ individuals for milk powder and tea production. Core activities included

• Supply planning based on demand forecasts,
• Production scheduling and manpower management,
• Predictive and preventive maintenance planning,

Major Achievements:

• Delivered an impressive 3.7% overall saving on Project Capex against the budget.
• Created and Implemented policies and procedures manual for ISO 22000 FSSC implemenation,
• Successfully completed Friesland Campina's rigorous pre-commissioning food safety audit for Foremost Milk Powder.
• Achieved a remarkable 80% Overall Equipment Efficiency (OEE) within the first six months of project commissioning.
• Maintained an exceptional 91% Output Reliability (OR).
• Achieved 8% improvement on labor productivity on YTD basis during 1st year of operations.

• Lead complete Production and Maintenance Operations of Fried Snacks Manufacturing Factory (Potato Chips, Peanuts and Nimco) at Hub Industrial Area.
• Managed a large and diverse team of 20 direct reportees and 500 contractual workers.

Major Achievements:

• 10% Reduction in FOH cost per kg resulting in a YTD saving of PKR. 11.4 Mn.
• 35% Reduction Packaging Material Wastage, reduced from 2.83% to 1.80%. Annualized cost saving of PKR 0.80 Mn.
• 10% Improvement in Labor Productivity (Kg/Man-hrs).
• 3% Improvement in Process Yield; increased from 24.8% to 25.7%
• 75% Improvement in MTBF; increased from 9.72 to 17.00 hrs.
• 35% Improvement in MTTR; decreased from 0.83 to 0.53 hrs.
• Streamlined Annual Capacity Planning through preparation of Annual Operating Plan (AOP) and Supply Planning Schedules as per Rolling Sales Forecast (RSF) for Pre & Executive S&OP.
• Optimized Process Parameters and improved OEE% of Packing Machines from 76% to 83% through effective use of Loss Tree Analysis and other TPM and Lean Manufacturing techniques.
• Prepared Capital and Revenue Budget for the factory. Achieved 6% saving on Revenue budget over the target via improved Autonomous and Planned Maintenance programs.

In addition to regular responsibilities, I led the implementation of the SAP PP module, overseeing its seamless integration with other modules. Played a key role in creating Business Process Maps, Business Blue Print Documents, Authorization Matrices, and End User Training Program. Ensured effective implementation and user readiness for enhanced operational efficiency.

• Led end-to-end operations of Biscuit Manufacturing on 7 production lines, overseeing 30+ packing machines
• Managed a diverse team of 18 permanent employees and over 1000 contractual workers
• Led the Annual Capacity Planning process at the Group Level, optimizing capacity utilization from 87% to 92% over three years based on Rolling Sales Forecast (RSF)
• Developed and implemented Supply Planning Schedules for Pre & Executive S&OP, ensuring an impressive Output Reliability Rate of 95% through effective collaboration with sales and logistics teams
• Implemented a comprehensive system for measuring the Overall Equipment Effectiveness (OEE%) of Packing Machines, resulting in an average OEE of 83%
• Ensured strict compliance with occupational health and safety rules, maintaining a safe working environment at the plant

Key Achievements:

• Successfully implemented rigorous time and motion studies, leading to a 14% reduction (175 workers) in the on-roll workforce and achieving a gross annual saving of PKR 40 million
• Optimized coding format, resulting in a significant 40% reduction in Thermal Printing cost, equivalent to a saving of PKR 20 million per annum
• Significantly increased Labor Productivity from 17 to 21 Kg/Man-hr over a three-year period
• Implemented effective measures to reduce Packaging Film Wastage by 15% in 2014, resulting in an annual saving of PKR 12 million
• Achieved a remarkable 16% reduction in Finished Product Wastage
• Successfully minimized Process Downtime by 18% over a three-year period
• Conducted an extensive study with the Finance Department to identify and address un-traced wastage, resulting in a 25% reduction in unaccounted losses
• Implemented Statistical Process Control (SPC) techniques, reducing giveaway (overweight product) losses to an impressive 0.2%
• Demonstrated a significant 30% decrease in customer complaints over a three-year period.

• Managed quality and SHE (Safety, Health, and Environment) matters at 3P sites for Detergents, Personal Products, and Tea, implementing Unilever Global Quality Standard for co-packers across all 3P units
• Enforced strict adherence to manufacturing processes in alignment with HACCP Guidelines, Unilever OHS FWS/OHSAS 18001:2007 Compliance, and EMS FWS/ISO 14001:2004 Compliance
• Spearheaded the implementation of the CRQS program, Quality Verification Program (QVP), and Enzyme Safety Protocol in Detergent Plants
• Conducted comprehensive Internal/External audits of Unilever factories/offices on a nationwide basis

Major Achievements:

• Developed and implemented a robust measurement and monitoring regime for Environmental KPIs across all 3P sites
• Prepared system procedures for environmental aspect impact assessment and conducted training
• Successfully completed annual quality and safety audits, ensuring the renewal of certifications by independent third-party auditors
• Oversaw the construction of a 400 Tons/Day Detergent Manufacturing Plant, maintaining Zero Lost Time Accidents throughout the project.

• Independently Lead Shift Operations Production Planning and Operations Management of Liquid Line (Pasteurization and UHT) and Powder Plant
• Prepared & maintained daily report on schedule adherence and Productivity status
• Minimized performance bottlenecks for achieving high productivity with minimum consumption of material & machine
• Supported the adherence of HSE and Food Safety Rules Compliance

Major Achievements:

• Successfully implemented a system for filling machines’ efficiency monitoring in 2008
• Performed the role of Project Coordinator (Processing) for installation and commissioning of 2nd Milk Pasteurization Plant
• Commissioning of Third Aseptic Tank (ATS) with GEA TDS in 2007
• HPO Storage and Dosing System as Project Team Member (Process Design)

• Shift Incharge on UOP Sinco Solid State Polycondensation (SSP) Plant for PET resin up-gradation.
• Traveled to job sites with senior personnel to aid in inspections and ongoing project observations.
• Interpreted blueprints and technical drawings to analyze upcoming projects.
• Maintained contemporary technical knowledge of engineering concepts.
• Constant Plant Monitoring through Delta V DCS.
• Production Plan Execution
• Trouble shooting and Trends’ study of key controllers.
• Exposure to Zimmer GmbH Polycondensation (POLYCON) plant for PET resin manufacturing.