Hafeez Ur Rehman

Experience

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  Shafi Gluco Chem (Pvt) Limited

  Feb 2004 - Mar 2005

  SHIFT INCHARGE LIQUID GLUCOSE PLANT

  Shafi Gluco Chem is a process plant to produce 70 TPD of Liquid Glucose.The plant is designed by STARCOSA Germany.Worked as Shift Incharge and responsible for all manufacturing/plant operation related activities during the shift.Hands-on experience of the following equipments and unit operations.Size Reduction (hammer mills),Solid Handling (pneumatic conveying ,bucket elevators and screw conveyors),Size Separation (vibro screens),Filtration (candle filters , plate and frame filter press), Drying(drum dryer),Condensation(shell and tube condensers),Evaporation (plate and frame evaporators).Also worked for a brown field project of same plant for the capacity enhancement of existing evaporation unit to meet the desired product specs. Show less

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  Security Papers Limited

  Mar 2005 - Apr 2006

  Assistant Manager Production

  Responsible for production planning activities to meet the raw material (pulp production) required by the down stream paper making section (Machine House).

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  Novatex Limited - Official Page

  Apr 2006 - Sept 2012

  Novatex Limited is a subsidiary of Gatron (Industries) Ltd-(Gatro-nova Group).It was a petrochemical complex having 02 Polymer (poly ethylene terephathalate) poly condensation Plants 600TPD & 300TPD respectively and 02 SSP (solid state polymerization) plants 300TPD each. Worked as a Shift Manager/Production Superintendent for whole complex (04 plants) and responsible for:•Safely meet and exceed production targets with minimum of waste and off spec per produced unit in all four plants.•Evaluation and implementation of initiatives for improved safety and performance of production machinery and processes.•Ensuring production systems are operated safely and efficiently.•Implementation of associated policies and procedures.•Responsible for production Operation team's competency, development of talent, training requirements and mentoring.•Participate in daily departmental coordination meeting with other plant discipline.•Supervise the product /material segregation according to grade and bagging operation. Show less Shift Incharge of Polymer (PET poly condensation) plant 600TPD at Novatex Limited.•Nominated as Incident Commander during the shift and responsible to lead any emergency situations related to plant safety in whole complex.•Responsible for the safe and smooth operation of the plant during the shift.•Involve in the planning and execution of planned and emergency shut downs of poly condensation plant.•Lead the trouble shootings with the shift team like power failures, cooling water failure,product conveying air failure,demin water system failure,chocking of barometric legs of condensers and product conveying lines. Show less 1-Worked as a Polymer plant Project,Commissioning and Start up Engineer for a new Polymer (Poly Ethylene Tera phthalate) plant having designed capacity of 600 tons/day designed by a Chinese company China Textile & Industrial Engineering Institute (CTIEI) at Novatex Ltd.Responsibilities:•Inspection of process piping with its auxiliaries according to Isometric drawings and Process & Instrument Diagram (P&ID’s) and kill the punch list of designated area. •Technical audit of process and ancillary equipment before installation in collaboration with contractors & other field disciplines.•Commissioning and start up of cooling towers.•Pressure Hold up Test (cold and hot conditions) & Helium Leak Test for Vacuum Tightness.•Level Calibration of process vessels, distillation column and Reactors.•Functional Test of pumps/Agitators/cutting units etc. •Inspection and audit of process equipment/Reactors before Box up along with the mechanical and CTIEI team.•Engage in plant Process Safety Management (PSM) by conducting small Process Hazard Analysis and participate in larger HAZOP.•Safe start up of poly condensation plant.2-Worked in the Commissioning and startup of dual fuel fired HTM (heat transfer media) oven (Siemens PLC operated “Schematic7”) along with the Chinese counterpart BSPC (Beijing Aerospace Petrochemical Technology Equipment engineering corporation) at Novatex Ltd. Show less

  • SHIFT PRODUCTION Manager POLYMER PLANTS

    Jan 2012 - Sept 2012

  • SHIFT INCHARGE POLYMER/PLASTIC PLANT

    Jan 2009 - Dec 2011

  • POLYMER PLANT PROJECT,COMMISSIONING AND STARTUP ENGINEER

    Nov 2007 - Dec 2008

  • POLYMER PLANT SHIFT OPERATION ENGINEER

    Apr 2006 - Oct 2007
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  Tuwairqi Steel Mills Limited

  Sept 2012 - Jun 2015

  MIDREX DRI Plant is a process plant for the direct reduction of iron ore with reducing gases CO & H2 to produce pure iron.Plant is control through HONEYWELL DCS (Experion C-200) and process/plant safety ensures through ESD/FSC (Fail Safe Controller).ROOTS compressors are control through Allen-Bradley (control logic 5561 series).BENTLAY NEVADA 3500 is use for vibration monitoring of Compressors, Fans and Blowers.Different Gas streams are monitored and analyze through online Analyzers and Mass spectrometers.Responsibilitlies:•Participates in advanced trouble shooting and coaches others to learn these skills.•Networks with other engineers on site to leverage knowledge on plant operations Example: Production, Improvement, etc. •Initiates changes to Plant Operating procedures to ensure they are valid and up to date. Works with Production personnel in this respect. •Ensure the Section's operational tasks meet corporate safety and environmental policy and standards. •Develop and review training needs of production staff, formulate and control shift personnel training in accordance to company's and section's training needs and requirements to enhance their operational skills and knowledge. •Assist the Operation's Manager regarding all manufacturing and maintenance-related activities in the section to ensure safe and stable operations and to meet production targets. •Developed procedures and once approved, supervise the implementation of procedures within plant equipment operation limits to prevent miss-operations and human errors in daily plant operations. Show less Worked for the cold and hot commission of Pakistan’s first DRI (Direct Reduction Iron) plant at TUWAIRQI STEEL Bin Qasim Karachi from 10th September 2012 to 12th Jan 2013.The plant is designed by MIDREX TECHNOLOGIES, INC.Charlotte, N.C., USA. Having designed capacity 1.28 MTPY.Worked for the commissioning of :• Reformer & Waste Heat Recovery.• Natural Gas loop (having safety management system,FSC-Fail safe control) for the reformer.• Fans and Blowers.• Centrifugal and Lobe type gas compressors.• Blowing of auxiliary and main burners of the reformer and process piping lines.• Actively participate in the PSSR (Pre Start up Safety Review) and lead the PSSR for Reformer,Heat recovery and natural gas station.• Develop commissioning procedures verified by the lead commissioning expert.• Prepare area wise daily commissioning report and submitted to plant manager.• Inspection and audit of process equipment before Final Box up along with the Lead Commissioning Expert.• Safe start-up of DRI plant. Show less

  • DEPUTY MANAGER/SECTION HEAD PRODUCTION DRI PROCESS PLANT

    Jan 2013 - Jun 2015

  • COMMISSIONING/START UP ENGINEER DRI PROCESS PLANT

    Sept 2012 - Jan 2013
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  Novatex Limited - Official Page

  Jul 2015 - Oct 2024

  Senior Manager/Head of Production (Bopet Packaging Film)

  Assignments:Responsible to Plan,Initiate and implement Section wise process & quality improvement activities resulting increase productivity and equipment running times while decreasing the down time and waste generation.Suggest and finalize (after negotiating with the licensor)modifications in the existing plant & new projects as well with respect to improvement/ease of operation, de-bottle necking and capacity enhancement.Startup & Shutdown:Planning & execution of shutdown and Start-up activities in coordination with services department and lead from Production side.Core Responsibilities:Currently working as Head of Production for 02 Production lines and several offline Production sections till packaging.Supervise the section heads to ensure quality product with optimum utilization of Man,Machine and Material.Working with other departments:Working closely with maintenance and services departments with respect to equipments preventive maintenance and performance on daily basis.Administrative Responsibilities & Authorities:Lead the manpower direct and indirect around 80 plus including Section Heads & engineers.Working closely with HR department for appraisal and strategic decisions regarding man power hiring, succession planning and retaining.Lead production planning and working closely with the marketing/sales department :1-Regarding cost effective/optimum product switch over along with customer focused production targets.2-Decision making regarding Plan changes during plant emergencies or plant upsets. Show less

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  Macpac Films Ltd

  Oct 2024 - now

  Factory Manager