Experience
Manager Production, Planning & Control
Atlas Honda Limited
May 2021 – Oct 2021 (5 months & 6 days)
Manager Research and Development (New Model Center)
Atlas Honda Limited
Apr 2020 – Apr 2021 (1 year & 1 month)
Assistant Manager Research and Development (New Model Center)
Atlas Honda Limited
May 2018 – Mar 2020 (1 year & 11 months)
Assistant Manager Production & Maintenance
Atlas Honda Limited
Sep 2014 – Apr 2018 (3 years & 8 months)
Management Trainee officer (MTO) Production and Maintenance
Atlas Honda Limited
Mar 2014 – Aug 2014 (6 months)
Maintenance Engineer
Dynamic Sportswear (Pvt.) Limited
Jan 2014 – Feb 2014 (2 months)
Projects
Project Leader for KVWM (Pridor CD-100 Motorcycle) Development
Atlas Honda Limited
- Optimizing and improving design of 79 parts for cost reduction, customer satisfaction and quality enhancement.
- Rs. 612 saved per unit motorcycle (cost reduction) by optimizing designs of various parts.
- Rs. 22, Rs. 33, Rs. 36, Rs. 37, Rs. 5 and Rs. 69 saved per unit motorcycle against “Sleeve RR Wheel”, “Head pipe”, “Stay cover”, “Cowl front”, “Stay winker” and “Side covers” respectively by negotiations with vendors. Overall Rs. 1423 saved per unit motorcycle by price negotiations with respective vendors.
- Warranty claims reduction from 0.593% to 0.441 % of annual production by improving design of parts. So 34.47% improvement in terms of warranty claims as compared to base model.
- Direct pass growth from 87.67% to 91.33 % of annual production. So 4.18% improvement in terms of direct pass as compared to base model.
- Tail light Assembly and Rear Fender Assembly jig design and fabrication in coordination with Assembly plant.
- Designing and fabrication of “process and inspection fixtures” for stay cover of frame body in coordination with frame body welding plant.
- Designing and fabrication of “front cowl” and “side covers” painting jigs in coordination with “ABS paint Plant”.
- Designing and supervising training of all manpower of “Frame body welding plant”, “Frame assembly plant” and “Fuel tank painting plant” for all the design change parts and processes.
- Successfully conducting and managing all major events (like PP1, PP3 and MP etc) as per guidelines of Honda Motors Japan.
- Taking counter-measures and closing all product problems (Hinanhyo’s) raised during PP1 & PP3 and getting it approved from Honda Motors Japan.
- Compiling and finalizing SAP based BOM “Bill of material” in coordination of PPC (Production planning department).
Co-Project Leader for KOKA (CB125F Motorcycle) Development
Atlas Honda Limited
- Optimizing and improving design of 358 parts for cost reduction, customer satisfaction and quality enhancement.
- 6752 saved per unit motorcycle by price negotiations with respective vendors.
- Warranty claims reduction from 2.82% to 2.27 % of annual production by improving design of parts. So 24.23% improvement in terms of warranty claims as compared to base model.
- Direct pass growth from 76.23% to 82.29 % of annual production. So 7.94% improvement in direct pass as compared to base model.
- Designing and fabrication of “process and inspection fixtures” for all design change parts.
- Designing and updating Quality management system (operation standards, PQCT’s, MQS, check-sheets etc.) of all in-house departments as well as all vendors, in coordination with respective departmental managers.
- Designing and supervising training of all manpower of for all the design change parts and processes.
- Successfully conducting and managing all major events (like PP1, PP2, PP3 and MP etc) as per guidelines of Honda Motors Japan.
- Taking counter-measures and closing all product problems (Hinanhyo’s) raised during PP1, PP2 & PP3 and getting it approved from Honda Motors Japan.
- Compiling and finalizing SAP based BOM “Bill of material” in coordination of PPC (Production planning department).
Project Leader of “1 Million to 1.25 Million Annual Plant Capacity Expansion Project” with budget of Rs. One Billion
Atlas Honda Limited
- Rs. 43.57 million saved as result of negotiations with maker & implementation of “early equipment maintenance” (TPM).
- Rs. 11.23 million saved as result of FOG (Lean manufacturing).
- Rs. 25, 11 and 14 saved as per crank shaft, cylinder head and crank case set respectively by achieving economies of scale.
- Successfully shifted 86 Machines with an average weight of 6 Tons to sister’s company and their re-installation along with their “Quality assurance confirmation” with no delay in production.
- Successfully planned (with suppliers for raw material) and built OIKOMI (safety stock) for machine’s transfer.
Kaizens & Operational Improvements
Atlas Honda Limited
Re-designed process flow and inspection stations in cam shaft manufacturing shop resulting 4% increase in annual capacity with saving of Rs. 108,285 per annum in tooling price.
Implemented KANBAN system in cam shaft machining area resulting in reduction of process rejection from 0.16% to 0.14% and improvement of 5S from 3.8 to 4.6 (out of 5) in first three months.
Modified machining processes and utilization of dead tooling for self-feeder machine resulting in cost saving of Rs. 558,822.
Manufactured lathe machine dead centers from life end carbide drills resulting Rs. 403,896 cost saving per annum.
Re-designed tapping machine head in cam shaft machining area to save maintenance cost of Rs. 268,000 per annum.
Developed process capability and monitoring boards for cam shaft manufacturing area resulting in straight pass improvement from 99.40% to 99.42% in first three months.
Designed time motion study of cam shaft machining area resulting in productivity rise from 75.2 to 81.3 pieces per person; designed grinding wheel balancing technique for cam shaft manufacturing area resulting in 5.11% rise in machine capacity.
Successfully developed a new source for mist collectors saving Rs. 55 Million.