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Position: Deputy Manger Process/Operations Location: Lahore, Pakistan Tenure: 26th Oct.2015 to Present (9 years & 4 months) Employer: Sanpak Engineering Industries (Pvt.) Ltd. Employer Information: • Sanpak Engineering is leading manufacturer of automobiles air conditioning system. • Sanpak is joint venture of Sanden Corporation Japan. • Sanpak is an ISO 9001-2015, ISO 14001-2015, ISO 45001:2018 & IATF 16949:2016 certified. Roles & Responsibilities:  Product study to identify processes and development of Process Flow Diagram.  Development of tooling & machines list required for product development.  Preparation of detail tooling development plan as per master schedule approved by customer.  Calculation of estimated tooling development cost.  Feasibility study for in-house or out sourced machining of tooling.  Calculation of process cycle time through Video time study & Direct time study for capacity and man power calculation and machine utilization.  Execution of tooling development plan with the help of development team.  Monitoring & controlling to ensure that tooling development is as per schedule and to initiate cost reduction programs.  Sample development for tooling trial and product validation.  Development & implementation of process design related documents like Control Plan & work instructions for standardization of processes.  Conduct Process Failure Mode & Effect Analysis on the basis of design Failure mode & effect analysis to identify and mitigate potential process failures.  Development of worker training plan to equip employees with the necessary knowledge and skills to perform their job effectively, efficiently, and safely.  Conducting Process Audits to review existing process control specifications to ensure that they are in accordance with changes in product specifications, process and quality improvements.  Method study for process improvement and to determine and recommend new process methodologies that will continually improve production methods and techniques.  Process Analysis through various quality tools & techniques to identify the cause of issue and to take appropriate actions to mitigate the issue.  Productivity enhancement through continues improvement & implementation of lean manufacturing.  Improve quality and efficiency by identifying and eliminating the root causes of variation in processes, minimizing defects, and achieving near-perfect quality levels through Six Sigma methodology.  Calculating OEE to improve the performance of manufacturing equipment through eliminating the sources of waste and inefficiency.  Layout design for ensuring smooth flow of work & material through a system.  Ensure continuous improvement by applying PDCA methodology.  Implementation of TPM activities on floor and check its effectiveness.  Implementation of poka yoke technique to prevent errors or mistakes in a process.  Ensuring the implementation of ISO 9001: 2015, ISO 14001: 2015, IATF 16949:2016 & ISO 45001: 2018.  Supervise and train staff to improve their performance and complete their tasks in more efficient way.

 Perform new product’s manufacturing studies and make production-efficient and cost-effective proto sample with the help of development team.  Identifying processes and making of Process Flow chart on the basis of approved proto sample.  Calculate, evaluate BOM (Bill of material) and BOQ (Bill of quantity) for each new project and entry into SAP.  Material issuance from Warehouse through entry by using SAP.  Identify and adopt new materials and processes to decrease cost and improve quality.  Time studies for each product in order to determine individual process cycle time and optimum manufacturing resources required.  Making of Production planning sheets on the basis of SAM calculated for each processes.  Identifying bottle neck process and balancing of line on the basis of SAM.  Calculating of machine utilization & Line capacity.  Layout design for ensuring smooth flow of work & material through a system.  Supervising the manufacturing processes, ensuring quality work is done in a safe, efficient manner.  Problem solving by applying 5 why Analysis & Root cause analysis.  Preparation of work instructions for standardization of processes.  Schedule regular maintenance for equipment.  Preparing daily production reports and sending to project manager through email.  Confirm the availability of stock for production by follow up with supply chain team.  Productivity enhancement through Lean principles & other IE tools & techniques.  Make proposal for new facility requirement.  5S implementation by giving training to workers and conducting periodic floor audits.  Make sure the quality on production line by making and implementing quality check sheets.  Employee trainings to reduce rejection rate.  Deliver the production to ware house through entry into SAP  Hazard identification, risk assessments and control implementation on production Floor