Rehman Ali

Experience

• 

  ICI Polyester

  Feb 2011 - Feb 2013

  Development & Laboratory Manager
• 

  ICI Pakistan

  Feb 2012 - Feb 2013

  Laboratory and Process Development Engineer Utilities

  Laboratory and Process Development Engineer Polymer / Utilities (June 2009 – 2011) • Implementation of SIRE coding on (230) Chemicals carried out • HS&E statistics report including Energy, H NPO( Hazardous non process output), NH NPO ( Non-hazardous non process output), Water, fuel usage and COD reporting on monthly basis to Corporate HSE Dept.• Re assessment of LAB chemical section Zone classification carried out after SIRE coding .As a result fire load of chemical section reduced by elimination of wooden furniture from Oil testing area ,also Zone classification tube lights and equipment installed .• Ensure that all Laboratory activities are carried out in such a way that all Safety and Health regulations are met and there is no recordable injury to any employee, contract staff or visitor.• Manage the introduction of new products and materials onto the manufacturing unit• Ensuring adequate QA/QC supervision on site and ensure procedures are followed. • Daily management of contractor interfaces. • Shut down and start up of CP polymer, use of glycol wash instead of TEG first time.• Development of operational staff on good manufacturing and continuous improvement activities• Develop the sites equipment and manufacturing efficiencies and capability• Management of allocated capital expenditure for development and strategic projects• Manage the introduction of new products and materials onto the manufacturing unitShift Coordination Manager (2006 – 2009) Show less

• 

  ICI Pakistan Limited

  Feb 2013 - Feb 2025

  Dedicated to delivering technical support to polymer industry enterprise, my focus is on enhancing product quality, ensuring plant safety, and achieving production, energy, and conversion efficiency goals. Proficient in new product development, I excel in aligning strategic aims with customer satisfaction and grievance resolution. My forte lies in propelling advancements in plant technology and facilitating future expansions through seamless collaboration with technology suppliers, while staying abreast of cutting-edge developments in polyester technology to inform future strategies and decision-making processes.• Ensure necessary technical support is available to meet business production, energy, and quality targets.• Suggest the latest modifications and improvements in the plant to achieve optimal outcomes and quality. Maintain healthy relationships with plant and technology OEM experts worldwide.• Oversee compliance with Health, Safety, and Environment (HSE) systems/procedures to sustain and improve business operations.• Ensure product quality meets standards through rigorous testing and quality control measures.• Advise on new improvements in product and technology, develop feasibilities to facilitate decision-making by senior management on key strategic projects.• Lead new initiatives from the worksite and mentor teams working on cost-saving and improvement projects outlined in the year-start strategic plans.• Develop and present CAPEX proposals to support plant growth and development.• Manage departmental fixed costs to align with budgetary constraints and ensure financial stability.• Conduct routine audits to ensure smooth and safe plant operations, identifying areas for improvement and corrective actions.• Collaborate with technology suppliers to foster continuous improvement and stay updated on advancements in the field.• Address customer complaints within predetermined reduction targets, aiming to enhance customer satisfaction and loyalty. Show less • Operation of 2 MW * 7 Dual fuel engines, 15 MW Circulating fluidized bed coal Plant, 5.67 MW gas turbine, and utility Plant containing water treatment , waste water, HVAC , Nitrogen production , Steam generation and Waste water Management .• Providing leadership and management to the facility’s staff to ensure that operations run smoothly and efficiently.• Creating a detailed list of goals and objectives for the department, which may include increasing efficiency, reducing costs, and improving employee morale.• Monitoring energy prices to ensure that the plant is running at a profitable energy mix.• Developing a plan for emergency response in case of equipment failure or other emergencies• Training new employees in proper safety procedures and emergency response plans• Maintaining equipment to ensure that it is operating properly and efficiently.• Identifying opportunities to reduce energy consumption through improved efficiency measures or by switching to alternative energy sources such as wind, solar, or hydroelectric power.• Overseeing the daily operations of the plant, including maintenance, repair, and hiring decisions Show less Currently working as Power Services and Utilities Manager , looking after recently commissioned two Coal fire boilers having total capacity of 100 Tons / hr , pressure 53 Bar. • 15 MW steam Turbine with 26 tons 20 bar extraction.• 45 Tons /hr EDI unit with double pass RO system.o Handling of 20 bar steam Gas/Furnace oil fire boilers.o 10.67 MW T-60 gas fire Turbineo 8000 Nm3/hr air compressing system ( 7 bar ) with heatless dyerso 2100 USRT chilling system ( compression & Absorption system)o 70 M3/hr compact treatment activated sludge method Effluent treatment Planto 240 Nm3/hr Nitrogen plant ( Cryogenic and PSA )o 5000 m3/hr cooling tower ( Pressure 6.5)o Water treatment plant having 45 m/hr RO , Demin and softening streams.o HVAC system having 35 supply units.o Raw water submersible tube wells with borehole capacity of total 1000 m3/hro Fire water ring management of 1000 m3/hr pumps with 4000 m3 pond and 12000 meter long network.o Handling of 1800 tons storage tanks of Heavy Fuel Oil with 100 tons daily handling. Reporting Team of 28 Managers, 20 Non Management and 36 Contractor staff.Responsibilities include troubleshooting, emergency handling, plant start up /shut down, planning and execution of Annual Turn Around and departmental budgeting. • Provide support to develop Business Strategy including efficiency improvement projects. Formulate and obtain approval of the capital budget and to ensure implementation of the same effectively for consistent improvement in the assets and ensuring availability of quality testing.• Ensure that all operations activities are carried out in such a way that all Safety and Health regulations are met and there is no record able injury to any employee, contract staff or visitor.• Develop manufacturing processes and management systems in utilities• Management of allocated capital expenditure for development and strategic projects for utilities Show less Currently working as Utilities Manager , looking after • 35 Tons /hr EDI unit for meet Demin water requirements.o Handling of 20 bar steam Gas/Furnace oil fire boilers.o 10.67 MW T-60 gas fire Turbineo 8000 Nm3/hr air compressing system ( 7 bar ) with heatless dyerso 2100 USRT chilling system ( compression & Absorption system)o 70 M3/hr compact treatment activated sludge method Effluent treatment Planto 240 Nm3/hr Nitrogen plant ( Cryogenic and PSA )o 5000 m3/hr cooling tower ( Pressure 6.5)o Water treatment plant having 45 m/hr RO , Demin and softening streams.o HVAC system having 35 supply units.o Raw water submersible tube wells with borehole capacity of total 1000 m3/hro Fire water ring management of 1000 m3/hr pumps with 4000 m3 pond and 12000 meter long network.o Handling of 1800 tons storage tanks of Heavy Fuel Oil with 100 tons daily handling. Reporting Team of 28 Managers, 20 Non Management and 36 Contractor staff.Responsibilities include troubleshooting, emergency handling, plant start up /shut down, planning and execution of Annual Turn Around and departmental budgeting. • Provide support to develop Business Strategy including efficiency improvement projects. Formulate and obtain approval of the capital budget and to ensure implementation of the same effectively for consistent improvement in the assets and ensuring availability of quality testing.• Ensure that all operations activities are carried out in such a way that all Safety and Health regulations are met and there is no record able injury to any employee, contract staff or visitor.• Develop manufacturing processes and management systems in utilities• Management of allocated capital expenditure for development and strategic projects for utilities Show less

  • Head of Technical Department

    Jan 2024 - Feb 2025

  • Head of Power Services

    Feb 2020 - Dec 2023

  • Plant Manager Utilities & Power

    Jul 2015 - Jan 2023

  • Plant Manager Utilities

    Feb 2013 - Jun 2015
• 

  LCI

  Feb 2025 - now

  Head of Production