Muhammad Kamran Abbasi

Experience

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  Fauji Fertilizer Company Limited

  Jun 2016 - Aug 2016

  Mechanical Engineering Intern

  ● Enhanced the efficiency of shell and tube heat exchangers through ANSYS Fluent simulations. Implemented design modifications such as tube inserts, multiple fins, deformed tubes, and helical baffles to improve heat transfer, reduce deposits, and minimize dead spots, optimizing performance for fluids with varying velocities and temperatures.● Gained hands-on experience with API standards, conducted technical plant visits, participated in orientation/training sessions, and documented weekly reports detailing key learnings and discussions with supervisors and team members. Show less

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  Ibrahim Fibres Ltd.

  Jun 2017 - Aug 2017

  Mechanical Engineering Intern

  ● Enhanced the efficiency of induced draft cooling towers by conducting thermodynamic calculations to optimize water outlet conditions, redesigning the water distribution system to increase air-water contact time, and selecting cellulose film fill to achieve a 15°C temperature drop in cooling water, improving heat transfer and reducing energy consumption.

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  Fauji Cement Company Limited Official

  Jul 2018 - Feb 2023

  ● Cost Optimization & Indigenization of Spare Parts:Spearheaded efforts to replace imported spare parts with local alternatives, resulting in PKR 22M annual savings. This initiative enhanced supply chain resilience, reduced procurement lead times, and supported local businesses.● Strategic Budgeting & Cost Management:Led CAPEX and OPEX budget preparation and management for spare parts, maintenance, and procurement, ensuring optimized resource allocation. Achieved 5% cost savings against a PKR 200M annual budget.● Cross-Functional Collaboration & Operational Efficiency:Worked with engineering, production, and maintenance teams to align material planning with operational needs. Reduced shutdown durations by 2 days and improved plant operational efficiency by 15%.● Data Analytics & Reporting:Utilized advanced data analytics tools integrated with SAP MM to track material and spare parts consumption, production output, and generate comprehensive monthly and yearly inventory reports for optimized planning and decision-making.● Continuous Improvement & Lean Practices:Led Kaizen events focused on material handling process optimization. Reduced material waste by 18%, saving PKR 75,000 annually, and contributed to continuous improvement initiatives in production.● Health, Safety & Environment (HSE) Leadership:Led HSE initiatives and conducted safety training programs for workers, resulting in a 20% reduction in accident rates relative to the previous year. Improved plant safety KPIs and supported the overall operational efficiency goals. Show less ● Material Forecasting & Demand Planning:Leveraged SAP MM and MRP tools for material forecasting, aligning procurement schedules with production needs. Reduced material shortages by 20% and avoided PKR 40M in emergency procurement costs by proactively predicting demand.● Inventory Management & Optimization:Led an inventory rationalization project, identifying and removing 7,829 obsolete items across multiple plants. Reduced total inventory value by 20.7%, saving PKR 25M and improving space utilization.● Supplier Relationship Management & Procurement:Negotiated long-term contracts with suppliers, leading to a 12% reduction in lead times and a 5% reduction in material costs. Saved PKR 15M annually by improving procurement efficiency and securing favorable terms for key materials.● Spare Parts Strategy & Maintenance Support:Developed and executed spare parts strategies for critical equipment, achieving 98% availability for key spares such as hammers, liners, nozzles, bearings, belts, pulleys, etc. Reduced downtime costs by 15% and ensured zero unplanned stoppages during peak production.● ERP System Transition & SAP MM Implementation:Played a key role in transitioning to SAP S4 Hana, particularly in the SAP MM module. Ensured accurate cataloging and classification of 26,000 inventory items, improving planning accuracy by 10% post-implementation.● BOM Development & Maintenance:Developed and maintained Bills of Materials (BOMs) for critical equipment such as rotary kilns, VRMs, packers, compressors, and pumps. Enhanced maintenance planning and reduced procurement delays by 10% by ensuring precise parts specifications. Show less ● Rotary Kiln Gearbox Overhaul:Assisted in diagnosing and overhauling the main gearbox (Flender P2DA) of the rotary kiln in the 7600 tons/day capacity ThyssenKrupp GmbH production line. Took ownership of critical maintenance tasks, ensuring smooth execution and leading efforts to minimize downtime, ultimately enabling the kiln to restart ahead of schedule and improve overall plant productivity.● Air Audit Implementation:Conducted an air audit in partnership with Atlas Copco, focusing on detecting air leaks in couplings, hoses, tubes, fittings, and pressure regulators throughout the plant.Achievement: Identified and fixed critical air leakages, resulting in cost savings of 8 million PKR/year.● Belt Bucket Elevator Installation & CommissioningContributed to the installation and commissioning of a 69.2-meter belt bucket elevator (Aumund make) at CF Silo-I in the 3700 tons/day FLSmidth plant, replacing the outdated airlift material transport system.Role: Project EngineerAchievement: Reduced power consumption by 73%, from 240kW to 65kW, optimizing energy efficiency.● Cement Packing Line Installation & CommissioningAssisted in the installation and commissioning of a new cement packing line, which included the integration of major equipment such as a belt bucket elevator, vibrating screen, and rotary packer (Haver & Boecker make).Role: Project EngineerAchievement: Increased cement dispatch capacity by 20%, enhancing operational throughput. Show less

  • Senior Assistant Manager - Spare Parts and Materials Planning Engineer

    Aug 2022 - Feb 2023

  • Assistant Manager - Spare Parts and Materials Planning Engineer

    Jul 2019 - Aug 2022

  • Management Trainee - Maintenance & Project Engineer

    Jul 2018 - Jun 2019
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  YANBU CEMENT COMPANY

  Feb 2023 - now

  ● Acting as a Key User from the warehouse department during the organization's transition from Oracle E-Business Suite (EBS) to Oracle Fusion Cloud, ensuring seamless data migration, process alignment, and adoption of cloud-based inventory management solutions.● Led inventory management for assets valuing over 200+ million SR, ensuring 99% accuracy in inventory records through regular audits and cycle counts.● Implemented strategies to handle obsolete, damaged/expired, and surplus materials, reducing holding costs by 15+ million SR.● Led a cross-functional team to implement a barcoding system for inventory tracking, resulting in a 42% reduction in inventory handling time and a 95% reduction in data entry errors.● Optimized inventory storage by strategically positioning fast-moving items, reducing work order processing time by an average of 5 minutes per order, and improving overall operational efficiency.● Increased warehouse storage capacity by 4% through the strategic installation of additional racks and stands, optimizing space utilization and enhancing operational efficiency.● Trained and supported junior team members on inventory management software and control procedures, fostering a culture of continuous improvement. Show less ● Monitored inventory levels and optimized reorder points to meet operational demands, reducing stockouts and overstock incidents by 8% through predictive demand analysis and effective inventory replenishment strategies.● Enhanced inventory turnover rates by 11% by analyzing usage patterns and aligning with procurement strategies.● Investigated and resolved discrepancies in physical and system records, implementing corrective actions that reduced errors by 27%.● Integrated project surplus materials into inventory, achieving a 2% reduction in procurement costs and enhancing resource utilization.● Optimized spare parts database by creating new item codes, revising descriptions, and merging duplicates, improving searchability and reducing redundancy.● Reengineered locator systems with a user-centric design, improving accessibility, operational clarity, and workflow efficiency across the warehouse.● Developed SOPs for disposal and write-off processes for expired and damaged inventory.● Detected and removed fake bearings from inventory to ensure accurate stock valuation.● Delivered detailed reports on stock levels, usage trends, and storage challenges on a regular basis, recommending actionable improvements to streamline operations.● Collaborated with warehouse teams to establish best practices for quality control, safety, and security, ensuring compliance with industry standards. Show less

  • Lead Inventory Control Specialist

    Dec 2024 - now

  • Inventory Control Specialist

    Feb 2023 - Dec 2024
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  Global Mentorship Initiative

  Feb 2025 - now

  Mentor

  Volunteering to mentor college or university students in Kenya, Africa, to prepare them for their first career job. I provide guidance in the following business areas:- Professional networking and LinkedIn- Career planning and SMART goals- Global business communication skills- Job search and interview best practices- How to excel in the workplace environment