Malik's Resume

Malik

Senior Manufacturing Engineer

Male

30 y/o

Production Project Management

Bangkok

Nationality Pakistan

Senior Manufacturing Engineer
Toyota Daihatsu Engineering and Manufacturing
2022.01-Current
(4 years)
Job Role To Enhance and Assist Asia Region Toyota Companies to improve their 5KPI's (Safety, Quality, Productivity, HRD & Cost) ● Working with 8 Plants of Toyota Asia Region including Toyota Motors Thailand (Samrong, Banpho and Gateway Plants) , Toyota Motors Vietnam , Toyota Motors Philippines , Toyota Kirloskar Motors (India) , KZ Motors (Taiwan) , ASSB (Malaysia) , Indus Motors (Pakistan) , Toyota Motors Indonesia ● Developing each country Assembly Manufacturing Plants to enhance their Safety Quality , Productivity , Cost and HRD KPI's. ● Support each plants for Smooth and Slim lauch of New Projects (Major Model Change , Minor Model Change , Takt Time Change ● Assisting each plant to Improve the Cost of Direct and Indirect Materials by Benchmarking Activity , Source change , Better Material with Cheaper Cost by doing Research and Development ● Improvement of Quality Defects (Shipment Quality , Built In Quality) by Quality PMR's , Toyota Production Systems and Lean Manufacturing ● Focusing on Producing Direct OK Delivery Ratio by reducing Repair Time ● Enhance each country's Production Capacity by PEFF and MPEFF implementation and Level up by PDCA ● Analysis on Production downtime by Root Cause Analysis and Kaizen to increase the Production Efficiency ● Develop each country's Process Design for a Levelled Production System (Heijunka) by Cycle Time versus Takt Time Analysis considering Space limitations ● Identify the Muda , Muri , Mura of each region to enhance Value Added Jobs and eliminate unnecessary Jobs ● Working on Asia CO2 Emmission Zero Target with each plant. ● Electric Vehicle (Hybrid , Mild Hybrid) - Working on Project Launch as Safety Trainer for Safe Process , Battery Assembly Line at TMT ● Procurement and Installation of Brake Oil Filling Machine , Fuel Dispensing Unit Achievements Projects ● New Model Launch (Gasoline , Electric Vehicle) Yaris (IMC - 2020, Pakistan) , Yaris (TMT - 2022. Thailand) , Yaris Cross (TMT - 2023, Thailand) Successfully worked on the launch of New Models in last couple of years with Pakistan and Thailand plants with No impact on current Quality. Achieved the Production efficiency at the time of Lauch to be 97% Target TMT, 95% Target IMC Instalation of battery assembly line at ASSB and TMT Plants for the 1st Time ● Takt Time Change with Sales Volume (Fluctuation) In last 2 Years every region comes with multiple changes in terms of Tak time based on Sales Volume. Developed a Flexible and Agile System for each region by improving Changpoint Management , Automation by Karakuri , Process Balancing (Yamazumi) , Improving 5s and 5 Fix Level and Process Standardization by Lean Manufacturing (Achieved Takt Time Changes --> TMT : 63 Sec to 55 Sec , TMV : 30 Mins to 63 Mins , IMC1 : 13 Mins to 11 Mins , IMC2 : 3.9 Mins to 3.7 Mins) Production ● Safety - Achieved Zero Fatal , Zero Stop-6 Accidents Trend in Asia Region (FY 2022 - FY 2023) ● Quality - Achieved Global Quality Target of 0.02 Defects Per Unit in Shipment Quality Standard for Asia Regaion Plants (FY 2022 - 2023) ● Efficiency - Achieved Production Efficiency Targets of Each Region specially Thailand Plant 97% (FY 2022 - 2023) ● Productivity - Achieved the PEFF Target of 1.00 for TMT, ASSB and TMV Plants (TMP and IMC In Progress)
Assistant Manager
Toyota Indus Motors Company
2021.01-2021.12
(a year)
Job Role To Support Production Assembly Trim , Chassis and Final Line from Engineering Perspective ● Trim, Chassis and Final Line Process Designing at Changepoints ● Developing of Standardized Work Chart , Standardized Work Table , Yamazumi (Cycle Time Plotting) , Work Instruction Sheets , Element Instruction Sheet ● Process Balacing by Eliminating Muda ● Procurement and Installation of Brake Oil Filling Machine , Fuel Dispensing Unit , Battery and Seats Manipulator ● Capacity Increment Project from Yearly Production of 66,000 Units Per Year to 76,000 Units Per Year ● Quality Defects Reduction Activity by Root Cause Analysis and Kaizen Achievements ● Enhanced Production Capacity of Assembly from 66,000 Units to 76,000 Units Per Year ● Achieved Quality Defects per Unit for SQA Target 0.05 DPU
Production Engineer
Toyota Indus Motors Company
2019.04-2020.12
(2 years)
Job Role Project of Yaris Launch to work as Final Line of Assembly Production Engineer ● Gentan-I Reduction at Final Line Direct Material ● Final Line Layout Change 23 Process to 21 Process ● Final Line Man Power Rduction from 46 Members to 43 Members Achievements ● Reduced the Direct Material Consumption by Wastage Reduction of AC Gas, Windshield Sealer (Cost Saved 115,000 USD) ● Process Balanced and Space Optimzed (Reduced 10 Meters Space)
Group Leader
Toyota Indus Motors Company
2018.04-2019.03
(a year)
Job Role To Lead the Team of 46 Members of Final Assembly Line and Quality Gate ● 46 Team Members and 5 Team Leaders Supervision and Daily Management ● To Monitor Daily 5 KPI's of Safety, Quality, productivity, Cost and HRD of the team ● To ensure the Absenteeism Management and control Changepoint ● To Develop Team Members Multiskill Processes ● To Ensure Zero outflow of Quality issues from Final Quality Gate ● Hazard Identification awareness and Develop Safety Awareness amongst the Team Achievements ● Achieved the Yearly Targets of Zero Accidents , Defects Per Unit Target Achieved , Achieved 92% Production Efficiency ● Increased the Multiskill Process Team members Development from 20 Members L3 on 3 to 35 Members L3 on 3