Usman Ejaz

Experience

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  Huffaz Seamless Pipes Industries

  Nov 2002 - Mar 2006

  Deputy Manager Production Planning & Control

  Leading complete Production Planning and Control of the sole manufacturer of seamless pipes in Pakistan, based on Hot Piercing and Cold Drawing. Conforming to ASTM, API, BS, JIS, and DIN standards while operating under an IMS certified to ISO 9001, 14001 and OHSAS 18001. Also was leading the affixed Huffaz Engineering Works specializing in Machining, Fabrication, Heat Treatment, Forging, & Casting, for hi-end products and mass production (team of 60+ personnel). Successfully developed & implemented ISO 9001 based QMS Product Range: Flanges, Sprockets, Mandrills, and Projects like SS impellers, train shafts, classified jobs Curtailed material losses by back-calculated planning of 12 manufacturing processes Secured more than $US 1M of orders by trouble shooting chronic production failures Balanced process loads and removed bottlenecks on the plant Show less

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  Engro Corp

  Mar 2006 - Jun 2013

  Reporting directly to VP Manufacturing I led Lean Six Sigma for 3 Fertilizer plants at Engro (formerly EXXON),Pakistan’s $US 1Billion conglomerate operating on world class standards Revitalized a challenged Six Sigma program through Top Management alignment Saved ~$US 3.5M through coaching & mentoring of 30+ YB & GB projects: Wrench time improvement Working capital reduction Optimization of plant energy index Improvements in Service Factor Improving assets control Overtime reductions Strategic alignment of Six Sigma Objectives with Organizational Priorities Trained 20 Green Belt, and 80 Yellow Belts 40% improvement in employees participation rate, trained resources, projects completion Developed Six Sigma Systems & KPIs through external global benchmarks Change Manager for $US1M SAP project at Manufacturing Division Pioneered “Six Sigma Top Gear” to generate 2000+ improvement opportunities Developed and certified a strong successor to ensure sustainability of program Show less Responsible for accelerating organizational change in the transformation project of Migration from Maximo to SAP at the Manufacturing Division. Strategies were developed and rolled out utilizing Six Sigma, GE's CAP (Change Acceleration Process) and SAP's Organizational Change Management. Also trained as a Power User in the Materials Management, Plant Maintenance and Quality Management modules of SAP, and responsible for overall Project Coordination under ASAP methodology. Developed As-Is and To-Be Blueprints for Maintenance and Supply Chain processes Led Change Management at entire Division (GE’s Change Acceleration Process & SAP’s OCM) Attended 14 days SIEMENS led Advanced Power User training for PM and MM Developed innovative training plans for entire Division (400+ users)  Manuals, smart procedures, email learning tutorials and video training modules for SAP PM processes Led Progress monitoring and coordination between Owner and Contractor (SIEMENS) during SAP PM and MM company-wide implementation Project. Developed RFP, Vendors interviews & evaluation, Developed Project Plan (ASAP Methodology) Show less Led all Six Sigma activities at the Technical Department while working as a project engineer for continuous improvement capital projects which included feasibility studies for new businesses. We worked throughout under a system that instilled excellence by implementing world class DuPont Safety & EXXON Engineering Standards supported by an IMS certified under ISO 9001 & 14000, and OHSAS 18001. As Six Sigma Coordinator: Led Six Sigma activities within the Technical Department Led multiple Green Belt and Yellow Belt projects Coaching and coordination of Six Sigma projects in the department Coordinated Six Sigma Tools Embedment trainings for Non-Management staff Developed Six Sigma engagement scheme for Non-Management Staff Coordinator for Integrated Management System auditsAs Process Improvement Project Engineer: Led multi-million dollar Process Improvement projects with high savings impact Project scheduling on MS Project, Class II cost estimation Developed improved process designing, Front End Engineering Design reviews Preparation of major procurement & construction contracts (US$ 1M+), bids evaluation Project lead with workforce of 500+ cross-functional team membersMajor Process Improvement Projects included $US1M Business Critical project on High Pressure Loop Contract negotiation to save cost by 20% High end Quality Management: >97% Radiography results (<3% reworks) $US 6.7M Workshop Expansion Project (Machine Shop, Fab Shop, Motorpool, Tool Rooms)  $US 50M Feasibility of new businesses for state of the art Fruit Juice and Rice Processing $US 6M Feasibility for Restructuring and Refurbishment of Ammonia Catacarb facility Show less

  • Six Sigma Black Belt, Program Leader Manufacturing Division

    Sept 2011 - Jun 2013

  • Organizational Change Manager: SAP Migration Project

    Apr 2011 - Feb 2012

  • Senior Projects Engineer / Six Sigma Coordinator

    Mar 2006 - Mar 2011
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  Nestlé

  Jul 2013 - Aug 2019

  Country Lean Manager / Six Sigma Black Belt

  COUNTRY MANAGER FOR LEAN SIX SIGMA (LSS)Working with Top Management and Zone Asia-Oceania-Africa (AOA) teams for growing the 9 Nestlé Pakistan businesses through a consumer driven “0 Waste, 1 Team, 100% Engagement” model Increased Lean Six Sigma engagement in the Market from 2 to all 9 businesses in 2 years Secured highest ever $US 9M annual savings for Pakistan Market 20 Green Belt, 150 White Belt, and 1000+ Go-See Think Do (Kaizen) projects Led 6 End to End business turnaround initiatives for achieving top & bottom line strategies Projects identification through bottom-up financial Loss Tree Analysis and top down contributor analysis Conducted Assessments of Nestlé sites across the country with reporting to Market & Zone Management Delivered numerous trainings on Excellence, Lean Six Sigma, Training Skills, Change Management Represented Pakistan Market in numerous international continuous improvement conferences Global benchmark at Nestlé for Lean Six Sigma implementation at Milk Collection Developed annual Operational Master Plans for strategies, KPIs and objectives cascading Weekly / Monthly operational reviews across the Market and with Zone AOA for stewardship Designed and conducted Customer & Consumer Value Proposition researches / interviews and workshops Led Value Stream Design Workshops across Technical, Supply Chain, HR, Finance, Procurement Launched Market Lean Office program for supporting Nestlé Global revamp of Information Flows Conceptualized and executed a 3 day Six Sigma Symposium in Pakistan Designed & launched communication strategies through physical and digital media Assigned by Top Management for strengthening the Innovation Program / Culture of the Market Strengthened new product innovations through Concept Refinements / Ideation workshops Show less

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  Chevron

  Sept 2019 - now

  Responsible for first time deployment of Lean Sigma program at Chevron Pakistan. Working with Top Management, Global Lean Sigma teams and Asia-Pakistan (AP) Leadership to deliver business results.− Developed Lean Sigma Roll Out Plan for Pakistan – taken as benchmark by AP Management− Accelerated leadership engagement across the value chain for roll out of priority projects− Delivered $320k savings through accelerated projects across Supply Chain, Manufacturing and Sales • 50+ projects identification through Value Stream Mapping across value chain • 20% Sales Rep productivity increase by financials driven customers rationalization • Constructed Overall Equipment Effectiveness (OEE) framework for Filling lines • 10% enhanced capacity on Filling Line through changeover times reduction • $200k worth Detention & Demurrages reduction project for imported supplies− Established Training and Development framework and delivered White Belt & Green Belt trainings− Delivered the first Online Green Belt training in Chevron Downstream & Chemicals with participants from 3 countries− Set Chevron Pakistan amongst leading countries for Strategy Cascading through Hoshin Kanri− Implemented Digital Solutions for better decision making and business continuity like PowerBI & MS Teams Show less

  • Global Lead Lean Six Sigma - Integrated Supply Chain

    May 2023 - now

  • Lean Six Sigma Advisor - Europe / Middle East / Africa / South Asia / Global Marine (ISC)

    Nov 2020 - now

  • Lean Sigma Lead - Pakistan

    Sept 2019 - Nov 2020