Contact
Muhammad Asam Zia
www.linkedin.com/in/muhammad- Lean Manufacturing, Engineering, Procurement, Design and Project
asam-zia-b7186a3a (LinkedIn) Management
Pakistan
Top Skills
5S Summary
Continuous Improvement
Experience of leadership, change management, project
FMCG
management, manufacturing, supply chain management.
Engineering background coupled with business and management
acumen gives unique blend of critical analysis skill that are proved
through successful deliveries of complex projects and turning around
factory performance
Specialist of cost reduction, manufacturing, operations and project
management
Experience of developing strategies, business continuity plans,
feasibilities for projects, manufacturing support for new launches
Experience in leading and maintaining industrial peace and harmony
for increased productivity and production whilst exceeding KPI’s and
bringing environmental hazard to a minimum
Extensive Leadership & recruiting experience as part of senior team
of leading manufacturing firm
Full time People & Career Management experience including
mentoring, coaching & performance management
Experience
PHILIP MORRIS (PAKISTAN) LIMITED
10 years 1 month
Engineering Manager
June 2014 - April 2016 (1 year 11 months)
Sahiwal
Managing multi-million USD annual budget (FME) for the factory operation and
capacity enhancement project budget (CapEx) of multi –million USD
Heading the entire Engineering operations including, Maintenance, projects,
Asset Management, Inventory management, Legal compliance
Increased manufacturing reliability by enhanced utilities uptime and
productivity initiatives
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Devising financial strategies to ensure cost avoidance and ensuring reduction
in FME costs through controlled growth in organization
Implementation of lean manufacturing tools, increased performance through
continuous engagement of workforce, implementation of literacy program for
illiterate workforce whilst induction of skilled labour and phasing out of illiterate
workforce to ensure maximum output
Development & implementation of preventative maintenance plans which
resulted in increased factory uptime and reduced the maintenance cost
Planning and implementation of Business Continuity Plans, including planning
and execution of capacity enhancement projects of multi-million USD.
Successfully met and exceeded production targets within the defined
parameter such as quality, productivity, cost, safety, delivery time, industrial /
environmental health, continuous improvement spirit and at given budget
which resulted in factory being declared as most cost effective production
centre in Pakistan
Implementation of Environment, Health & Safety procedures and ISO
certification of the factory
Manager Planning & Execution Project IBEX
April 2012 - May 2014 (2 years 2 months)
Karachi
Planning and Budgeting of complete project of USD 56 Mio including
infrastructure development, Design Engineering, administration & technical
permitting, Building , Utilities, Information services, security,process equipment
Detail engineering design of project including civil, mechanical & electrical by
3rd party and in-house validation by project team by coordination with regional
team to ensure compliance with PMI procedures
Developed strategy to minimize the project execution timeline and cost.
Established, hired and completed project organization for brown field project in
Kotri & Sahiwal
Achieved one million safe man-hours without any accident during coarse of
execution of project
Responsible for making strategies for fund disbursements based on criticality
of activities and output, ensuring the project deadline is met
Ensuring Project Execution Plan incorporates best practices for project
reporting and Project Control (cost & time) and coordination with technical and
execution departments
Completed brown field project of Kotri factory which includes installation of new
primary line worth USD 32 Mio in committed timeline and budget
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Completed utilities upgrade including, electrical infrastructure upgrade,
generators, boilers, compressors, WWTP, air-conditioning in Sahiwal worth
USD 8 Mio.
Contractor Management for the complete project
Contract management for the complete project
Subject Matter Expert Factory Operations (SAP-P1 Implementation)
January 2012 - March 2012 (3 months)
Karachi
Aligned local SAP system with PMI SAP system
Developed existing process mapping system for factories.
Developed to be process mapping for factories without conflict.
Factory Engineer
July 2011 - December 2011 (6 months)
Sahiwal
Developed strategy for preventive maintenance of utilities
Ensured continuous supply of electricity, compressed air, steam, vacuum,
chilled water to the factory without breakdown
Devised a backup utility strategy to ensure proper utilization of assets by
capacity management.
Managed & completed factory capex projects of $ 5 Mio.
Responsible for setting milestones and KPI’s to measure engineering
performance and efficiency
Manager Primary Processing
July 2009 - June 2011 (2 years)
Sahiwal
Devised strategy to operate primary at its maximum capacity due to loss of
Karachi factory by supporting organization to deliver production targets without
any loss to the market share.
Developed organizational capability equipped with blend of soft and technical
skills by mentoring and project assignments to ensure quality talent available
to cater market requirements.
Development and implementation of STPs for primary processing to accurately
forecast production requirements to avoid inventory cost
Implemented lean manufacturing techniques to maximize business
advantages and consistently improved primary yield starting from 103% to
104%
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Initiated short recovery addback from secondary to maximize use of tobacco
for improved performance of tobacco utilization and minimizing tobacco
wastage
Implemented ripper yield monitoring and mass balance exercise to gauge
accountable and unaccountable losses for improved manufacturing
performance
Achieved best KPIs for primary processing in Pakistan for year 2011
Managed machinery upgrade project in primary for $ 1.0 Mio
Planned activities and implemented product traceability system and
successfully achieved intertek license for export to KSA market.
Assistant Manager Primary Processing
July 2007 - June 2009 (2 years)
Sahiwal
Daily production plan development based on SKUs volume to accurately cater
secondary requirements by assuring zero downtime due to unavailability of
cutfiller
Developed and implemented preventive maintenance plan and primary uptime
monitoring system to guage efficiency of preventive maintenance plans
Developed a system for KPI monitoring on daily basis and used analytical
techniques to measure favourable and unfavourable elements through PDCA.
Management Trainee
April 2006 - June 2007 (1 year 3 months)
Sahiwal
Process mapping of factory.
5S implementation
Poka Yoke implementation
Kanban implementation
Education
University of Engineering and Technology, Lahore
Bachelor of Engineering (BE), Industrial & Manufacturing · (2002 - 2006)
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