Usama Ali
Plant Manager at PTI-QCS- Claim this Profile
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English Native or bilingual proficiency
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Urdu Native or bilingual proficiency
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French Elementary proficiency
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Arabic Limited working proficiency
Topline Score
Bio
Credentials
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Certified Six Sigma Green Belt
ASQ - World Headquarters -
Siemens Mechatronic Systems Certificate
Siemens
Experience
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PTI-QCS
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United States
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Motor Vehicle Manufacturing
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100 - 200 Employee
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Plant Manager
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Sep 2022 - Present
- Ideate and implement strategic visions to create and improve production, quality, and labor utilization throughout the facility.- Provide the leadership needed to ensure effective utilization of plant personnel and equipment.- Collaborate with functional departments in the implementation of all continuous improvement activities.- Investigate and implement innovative methods of manufacturing processes to reduce costs and improve quality of the product.- Apply lean manufacturing principles to design, specify, and validate world-class manufacturing processes to achieve organizational goals.- Ensure that all process line schedules are in accordance with facility capabilities, customer requirements, economic performance, and planning, expediting as needed.- Direct and manage the establishment and maintenance of material replenishment methods, quality standards, and performance metrics in support of the organizational goals and objectives.- Budget and manage manufacturing cost structures by developing and maintaining operational expenses within budget allowance, and investigate cost-reduction measures to monitor P&L.- Create documentation protocols and ensure that all operations records are properly maintained and reviewed.
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Program Manager
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Sep 2020 - Sep 2022
- Engineering and Planning (EPC) for a new launch of automotive coatings facility.- Creating the process flow of product from raw material to finished good.- Working with vendors to ensure on time delivery and installation of equipment.- Initiating the project and running first part off the line.- Streamlining efficiency for optimum performance and process control.- Monitoring and reporting various data sets and KPI's for Stakeholder's meetings to ensure all financial goals are met.- Develop & design documents, user guides, maintenance documents, project documentation, and release documents.
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Manufacturing Process Engineer
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Jun 2019 - Sep 2020
- Applying engineering knowledge to control all the manufacturing processes through automated systems.- Continuous Improvement Projects: Increasing efficiencies in different areas of manufacturing like manpower and consumption of consumables. - Optimizing processes to decrease downtime and quality defects to increase OEE.- Using various methods of problem solving for root cause analysis and implementing permanent corrective actions to problems identified on the floor.- Creating prototypes for masking and hooks for experimentation of various designs.- Working and negotiating with vendors to procure on-time and most cost effective results.
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UTIL
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Italy
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Motor Vehicle Parts Manufacturing
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100 - 200 Employee
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Production Supervisor
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Nov 2017 - Nov 2018
Operations Management - Lead the manufacturing process by directing the activities of unionized Production and QC team members including manpower assignments, coaching safety, 5S, initiating performance improvement plans, conflict resolution, conducting annual performance appraisal, and other employee relations matters. Production Planning - Review production order requirements using SAP (ERP Software) and determine unit schedule for production. Review inventory levels and customer requirements to determine priority of production making sure customer expectations are met. Departmental Coordination - Work closely with Maintenance crew and Toolmakers to minimize machine downtime by identifying root cause, ensuring timeliness of repair operation, coordinating necessary support departments, and following up on corrective actions to avoid future breakdowns. Inspecting operating equipment and working environment for safety. Product Quality and Process Improvement - Ensuring APQP targets are achieved by monitoring program timeline and initiating corrective action to correct any negative variances to remove non-value-added activities. Providing productivity data for departmental reports (PPAP, Poka Yoke, 8D’s, 4M Fishbone diagram, time study, TAKT time, JPH). Audit Support - Ensuring quality of process/products by maintaining SPC data sheets and Part Inspection sheets. Implementing all procedures and quality documents on the floor to assist in IATF 16949 and ISO 9001 audits. CI Coordination - Using Lean methods. Reviewing all suggestions made by team members. Coordinating resources for implementation. Making recommendations for productivity & safety improvements to Production Manager. Ensuring Supplier quality standards are met. Identifying and coordinating training requirements and maintain skill chart for team members. Project Management – Increased production output from Welder unit by 30% through Preventive Maintenance; saving the plant over $300,000 annually.
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FCA Fiat Chrysler Automobiles
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United Kingdom
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Motor Vehicle Manufacturing
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700 & Above Employee
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Professional Maintenance Specialist
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Oct 2016 - Sep 2017
Maintenance Operations Management - Responsible for assisting and coaching unionized skilled trades, team leaders and team members on daily maintenance operations and SOP’s in support of the production process. Maintenance Planning - Support automation and controls of manufacturing process, plan project operations that establish priorities and sequences for the manufacturing product utilizing knowledge of trades, methods, machinery and equipment capabilities, and manpower requirements to coordinate activities according to OEM and WCM standards. PLC Support - Coordinate the operations and training of standard maintenance procedures (SMP), CMMS Total Maintenance System (TMS) and plant programs with RS Logic, PLC-5, Control Logics, Allen Bradley Drive Systems, machine installation, robotic automation and application. Preventive and Predictive Maintenance - Analyzing equipment in Assembly area (COMAU, ABB, FANUC Robots) and Pressroom (Schuler, VERSON, Danly Presses) to create machine component ledger calendars for periodic maintenance through FMEA (Failure Mode Effect Analysis), Drawings and Dimensions (GD&T) and Root cause analysis to impact OEE (overall equipment effectiveness). Project Lead- 1. Introducing Thermal imaging techniques for Preventive Maintenance of electrical equipment across the plant to increase MTBF & save more than $320,000 in annual maintenance costs. 2. Using DMAIC approach to reorganize equipment manuals and documentation to reduce MTTR, eliminate non value added activities and reduce breakdown analysis time by 40%. KPI Tracking - Experience with body shop, stamping press automation and sub-assemblies using metrics for LEAN principles and KPI tracking by means of pareto charts and pivot tables. 500K Club Member - Proud member of the 500K club at Warren Stamping FCA US for saving more than $500k in savings within the same fiscal year by implementing PDCA Kaizens and Continuous Improvement projects.
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Magna International
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Canada
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Motor Vehicle Manufacturing
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700 & Above Employee
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Quality Supervisor
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Oct 2015 - Oct 2016
Quality Assurance - Working in an automotive manufacturing environment for offline quality check of injection molding products for different programs of TMMC, Ford, GM and Honda. Identifying flaws in the parts and documenting it for continuous improvement following ISO 9001/TS 16949, JIT and Kanban standards. Using precision and calibration tools to test different parts and rectifying customer complaints. SPC Data Analysis - Preparing GP-12 audit reports for Quality Assurance data assisting in safe launch for new model parts. Corresponding with Quality Manager to sign off boundary samples and explaining quality alerts to operators.
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Solarize Pakistan Ltd.
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2802 Flintrock Trace, #271 Austin, TX 78738
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Junior Project Coordinator
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Jun 2015 - Sep 2015
Assist with management duties focusing on project deliverables, helping to keep time, cost, scope and quality on track for 49 MW Solar power plant. Dealing with Engineering, Procurement and Construction (EPC) vendors to meet project objectives; using Microsoft Project and Gantt Charts for resources/material estimation. Handling project communications and conforming to project quality and performance standards. Assist with management duties focusing on project deliverables, helping to keep time, cost, scope and quality on track for 49 MW Solar power plant. Dealing with Engineering, Procurement and Construction (EPC) vendors to meet project objectives; using Microsoft Project and Gantt Charts for resources/material estimation. Handling project communications and conforming to project quality and performance standards.
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Qauid e Azam Solar Power Private Ltd.
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Qauid e Azam Solar Park,Bahawalpur, Pakistan
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Solar Energy Engineer - Intern
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May 2015 - Jun 2015
Inspection of: •PV Modules Review •132KV Substation Design •SVC Station review •Monitoring System •String Combiner Box Connectivity •Inverter Testing •132KV Power Transformers •33KV Box Transformers •Switchyard Equipment •VSAT Communication Inspection of: •PV Modules Review •132KV Substation Design •SVC Station review •Monitoring System •String Combiner Box Connectivity •Inverter Testing •132KV Power Transformers •33KV Box Transformers •Switchyard Equipment •VSAT Communication
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Descon Integrated Projects Limited (DIPL)
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Pakistan
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Oil and Gas
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200 - 300 Employee
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Plant Design Engineer - Intern
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Jun 2013 - Aug 2013
•Pipe sizing and routing through Oil and Gas Plants. •Control of Valves and other instrumentation. •Plant Layout design. •NavisWorks - AutoDesk •Pipe sizing and routing through Oil and Gas Plants. •Control of Valves and other instrumentation. •Plant Layout design. •NavisWorks - AutoDesk
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Education
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2021 - 2023
University of Windsor
Master of Engineering - MEng, Engineering/Industrial Management -
2011 - 2015
University of Engineering and Technology, Lahore
Bachelor’s Degree, Mechanical Engineering -
2009 - 2011
Government College University, Lahore
High School, Pre-Engineering
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