Currently working as a Sr. Engineer- Incoming Quality Control, in past worked as the incharge of quality control in Refrigerator, Computerized Performance Testing (CPT), Deep Freezer, Split Air Conditioner and Microwave Oven departments. Also contributed in promoting lean and kaizen activities as a part of Kaizen Core Committee.
Incoming Quality Control (IQC):
– Ensured the timely inspection of material coming from vendors
– Developed procedures, Inspection Quality Plans (IQP), Inspection and Testing Instructions (ITI)
– Improved the quality of Deep Freezer fan motors and Refrigerator, Deep Freezer Inverter PCB Kits
– Liaison with local and foreign suppliers to improve the quality of products
– Conducted meetings and made action plans with vendors on arrival of faulty lots
– Proposed the standardized packing of common imported items coming from different suppliers
– Prepared and sent the technical feedback reports to suppliers for imported items and proposed corrective actions to avoid production loss
– Conducted technical trainings of staff and workers for better inspection
– Prepared the material rejection reports for reimbursement from the vendors as per agreements
– Developed strong liaison between R&D, Vendor Development, Foreign Procurement, Local Buying & Production
– Prepared monthly reports of different faults highlighted at IQC from suppliers and took subsequent corrective actions
– Upgraded the testing facilities of Incoming Quality Control department by adding new testing machines
– Worked as a team member in Supplier Improvement Program (SIP) to improve the supplier’s quality standards
– Coordinated for ISO 9001:2015 audits
– Conducted Supplier Assessments by visiting supplier’s manufacturing facilities
– Conducted quarterly material health audits
Refrigerator Department:
– Performed duties as a shift incharge and ensured the implementation of quality standards
– Contributed in upgradation of production line with PLIS-5 and Agramkow equipment and run the successful trials
– Reduced the freezer leakage complaint by 5%
– Prepared the material handling guidelines for finish goods store
Computerized Performance Testing (CPT):
– Expert of Computerized Performance Testing with hands on experience of PLIS-5 software and hardware
– Responsible to perform 100% testing of all refrigerators and deep freezers being manufactured
– To conduct the initial testing of new models and present the results to management for better decision making
– To add the new models in PLIS 5 and construct their testing limits
– Conducted record keeping, reporting and different performance testing
Deep Freezer Department:
– Lead the Deep Freezer section’s Quality team
– Contributed in upgradation of production line with PLIS-5 and Agramkow equipment and run the successful trials
– Upgraded DF production line for R-600 flammable gas and arranged subsequent safety measures
– Run the PLIS-5 successfully
Split Air Conditioner (SAC) & Microwave Oven (MWO) Department:
– Lead the SAC & MWO’s quality team
– Implemented Control Charts for Controlling Leakages at Leakage checking stage
– Coordinated for Panasonic Split AC project from QC&A side to present and ensure the fulfillment of Panasonic requirements
– Made the procedures and implemented the Outgoing Quality Control
– Made the procedures for the Reliability Test and implemented the same
– Made the procedures for the Quality Accidents/ Emergency Situation
– Made Inspection and Testing Instructions (ITI) for SAC and MWO
– Made and implemented process audit procedures
Panasonic Split Air Conditioner Project:
– Coordinated Panasonic Split Air Conditioner assembling project
– Prepared the documentation and QMS for external audits
– Conducted meetings with Panasonic team regarding their requirement and improvements
– Implemented improvements proposed by Panasonic team
– Conducted IQC on receiving of Split AC consignments and shared the reports with Panasonic team
– Supervised to ensure the best quality of Panasonic Split Air Conditioners assembly
– Conducted LQC and OQC on behalf of Panasonic team and shared the reports with Panasonic team
– Conducted sample production audits and mass production audits along with Panasonic team via online video calling and shared the reports with Panasonic team afterward
– Developed strong liaison with Panasonic team to ensure best quality of product
– Reported after sales faults and issue based on market feedback with Panasonic team to ensure quality
Manufacturing Execution System (MES):
An IT based software to manage the quality of manufacturing process and units—including quality deviations and exceptions instead of doing it manually by checklists.
– Devised the framework to replace the manual checklist filling IT based system on android devices
– Coordinated with IT team for development of MES system
– Conducted trial of MES system on shop floors, assembly lines and packing lines
– Launched the MES system in Water Dispenser department, Washing Machine department, Split Air Conditioner department and Microwave Oven department
– Developed the reports on Power BI
Field Visits:
– Conducted field visits to customer services centers, warehouses, dealers and markets to get feedback about product quality
– Identified the points of improvement observed during field visits
– Proposed corrective actions to improve the product quality
– Ensured to implementation of the corrective action
– Performed the audits of Customer Services Centre and Area Warehouses
– Conducted technical trainings of customer services staff to tackle the issues in better and efficient way
– Conducted the awareness sessions regarding product quality and unique features to customer services staff
Daily Product Audit:
– Conducted audits of Refrigerator, Deep Freezer, Water Dispenser, Split Air Conditioners and Microwave Oven
– Prepared daily reports of audits and emailed to all concerns
– Prepared weekly and monthly summary reports and conducted meetings to resolve and eliminate repetitive issues observed in daily audits
Lean, Kaizen, 5S Program & Process Improvement:
– Member of Lean, Kaizen and 5S Core Committee
– Conducted three annual Kaizen Ceremonies
– Saved 40 million PKR through Kaizen program in three years
– Implemented 5S in Incoming Quality Control & Press Shop Deep Freeze
– Conducted Time & Motion (DTS) Study in AC & MWO & Press Shop DF sections to enhance overall productivity

– SPC Implementation: Implemented Statistical Process Control on the data of previous three years to effectively check and improve the quality of lots of paper being manufactured at PM-6 in BSPL

– Gap Analysis: Analyzed the ideal & on-going practices and identified the key factors for improvement

– Report Writing: Presented a compact report with concise recommendations to develop and implement a proper SPC system and to make the paper quality consistent to the higher management