Usama Qureshi

Experience

• 

  SNGPL

  Jun 2015 - Jun 2015

  Project Intern

  - Designed and exercised a reverse lock mechanism for the domestic and commercial meters, capable of restricting the reverse flow of gas up to 75% and averting the gas theft at consumer end.- Improved layout of workshops at Central Metering Unit.- Revised SOP's in an aspect of QMS & HSE.

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  Sapphire Finishing Mills Limited

  Apr 2016 - Dec 2017

  Industrial Engineer

  Served in Industrial Engineering and Compliance Department and worked on diverse tasks including Lean Manufacturing, System Development, Workers Training and Data Analysis with the goal of Continuous Process Improvement & Optimization.- Implemented Lean Manufacturing techniques & optimized production processes to enable the organization to increase its operating efficiency.- Introduced and implemented 5S throughout the production floor. Trained the trainers and built 5S team to ensure on floor sustainability of 5S practices.- Implemented FIFO (first-in, first-out) in dyes and chemicals store and determined maximum stock levels.- Reduced chemical wastages up to 7% by employing secondary containment pallets, drum trucks and drum pumps. Moreover, trained chemical makers on safe chemical handling.- Developed Quality Management Standards and ensured their implementation.- Designed Emergency Evacuation Maps for production floors and utility areas.- Created a database, which monitored the validation and calibration of all production & labs equipment.- Responsible for performing Pareto Analysis of the defects and customer complaints on weekly and monthly basis to highlight significant issues to be discussed in meetings with production team.- Managing the quality and social audits by customers including VF, The children's place, Levis, Zara etc.- Played a role in Sustainable Development activities. Show less

• 

  Master Group of Industries

  Jun 2018 - Aug 2019

  Production Executive

  Reporting to GM and responsible for performing following tasks:- Execute and meet production targets.- Time study of new and revised products and calculate standard allowable minutes for them.- Execute tasks & projects related metal fabrications and overlook the Machine Shop.- Document and maintain the Bill of Materials for all products.- Analyze and improve production layouts in the aspect of productivity and safety, document them through proper drawings and maintain detailed record of all factory layouts.- Remove bottlenecks and increase efficiency.- Employ lean manufacturing tools to identify and remove the major wastage in production.- Identify and redesign jobs that are ergonomically unfit and may cause musculoskeletal disorders in workers.- Design jigs and fixtures for sustainable quality product.- Ensure the development and documentation of SOPs & Work Instructions for complete production processes and ensure their implementation in order to go for ISO 9001 certification in future.- Implement & maintain 5S all over the Production, Maintenance and Store areas.- Ensure proper training of all production staff on best practices regarding 5S, Safety & Quality Management SOPs. Show less

• 

  Interloop Limited

  Aug 2019 - now

  Leading Knit to Pack planning of 300 Knitting machines producing 12000 dozens of socks per day.- Ensure production readiness and plan pre-production trial activities.- Devise Fast React plan of coming week to ensure timely availability of production requisites like Yarns, Materials, and Packaging & Cartons according to Just-in-Time inventory management.- Coordination with all stakeholders including Inventory, Operations, Technical, Quality & Trial teams for smooth sailing of plans.- Cater to variation in customer demands with agility and cost effective manner.- Accomplishment of partial automation in Knitting & Finishing daily plans in coordination with IT team in Hosiery Manufacturing System.- Successful implementation of Advance Batch Making module in ERP.- Daily overall WIP levels down by 40% by devising better planning.- 50% reduction in leftover by improving lead times.- Implementation of Single Forward Flow of goods down the value stream & reduced transportation and touch points & saved 50% head count of WIP transportation team. Show less Leading section in Finishing department and responsible for daily production of 12,000 dozens of socks.- Execution of the daily production plans in all three shifts utilizing a team of over 200 personnel.- Ensure on time shifting of orders to FGS.- Coordination with planning team for capacity management.- Maintain the WIP stock within defined levels.- Keep track of KPIs like production efficiency, rework percentage, waste percentage etc. and ensure their compliance.- Ensure the Quality Index at Inline and Final Quality Control.- Pre-production test runs of new products with Product Development team.- Compliance of safety, quality and productivity standards on the production floor.- Provision of support to IE team for new projects regarding manpower utilization, job enrichment, new gadgets and process improvement etc.- Communication with merchants to resolve issues.- Taking A3 and Kaizen projects for top issues on monthly basis. Show less

  • Assistant Manager Industrial Engineering

    Jul 2023 - now

  • Senior Officer - Production Planning & Control

    Jul 2021 - Jun 2023

  • Senior Production Engineer

    Aug 2019 - Jul 2021