Engineer Project Manager

Zaffar A. Akbar

Greater Atlanta Area 678-***-**** acavpd@r.postjobfree.com

www.linkedin.com/in/zakbar1

Operations Manager / Production Manager / Project Engineer

Well-rounded, collaborative, and solutions-oriented operations leader,

production manager, and project engineer. Known as a tireless leader who

meets or exceeds production goals including quality, delivery, cost,

safety, productivity, downtime, and scrap. Strong analytical, budgeting,

planning, decision-making, process improvement, problem-solving, and

project management skills. Bachelor's degree in mechanical engineering;

M.B.A. Core competencies include:

. Operations leadership: As a manufacturing unit manager at Yamaha, led a

team of 136 employees, including seven direct reports, with an annual

conversion cost of product at $15M. Launched a new $16M production line

with complete hiring and training of 25+ new associates (total manpower

of 60). Reduced total recordable incident rates (TRIR) to less than that

of the administrative office in 2012; improved labor hours per incident

by over 200%.

. Production management: At Yamaha, improved OEE for a 12-year-old paint

line by 78% in a two-year effort with minimum capital investment. Reduced

overall assembled unit cost from $145 per unit to less than $100 over

three years. Reduced WIP and rework inventory by 81%. Flex budget in 2012

was favorable by 2% (for a $10M expense budget). Reduced downtime from

90+ minutes per day (two shifts) to less than 30 minutes per day.

. Project engineering: In the past 18 years, worked on 25+ projects that

had a budget of at least $2M; cumulative value is $1.1B. The largest was

at Decostar; served as project manager and lead project engineer for a

greenfield installation and startup of a 350K SF, 30-acre, $100M auto

parts plant in Carrollton. At Haden, served as project engineer or lead

engineer on 20+ industrial construction, expansion, and modification

projects for companies like Ford, GM, Toyota, Chrysler, and Boeing.

Professional Experience

2005 - Present Yamaha Motor Manufacturing Corporation Newnan, Georgia

YMMC manufactures and sells recreational vehicles - all terrain vehicles,

golf cars and personal watercraft. At its peak, this site built 220K (now

120K) vehicles per year, had $1B+ in sales and employed 1200+ people.

Unit Manager

. Led a team of 136 employees, including seven direct reports, with an

annual conversion cost of product at $15M.

. Managed three-shift operation with four fully automated pretreatment,

powder, and two-component (2K) robotic paint lines for Class A finish of

metal, ABS, TPO, and SMC bodies for golf cars, ATV's, and personal water

craft.

. Translated strategic objectives into short and long-term goals to deploy,

manage, and execute activities. Used MBOs for self, direct reports, and

supervisors. Developed and managed operations budget.

. Set and communicated high expectations and performance standards to

employees with measurable objectives. Eliminated roadblocks and provided

tools, work instructions, training, and development. Ensured timely and

comprehensive reviews, and fair and consistent accountability.

Implemented standardized work.

. Used key performance indicators (KPI) and visual controls with data,

charts, SPC, and Genba boards to track, communicate, and improve quality,

delivery, cost, safety, productivity, downtime, and scrap.

. Utilized Lean, 5S, autonomous maintenance (AM), Kaizens, PDCA, TPM, 4M, 5-

Why, fishbone analysis, and change-over reduction to drive costs and

wastes out of the operation while simultaneously improving quality.

. Manage new model launches. Review and manage PPAP, work instructions,

process change / change point, operator training, and control plans.

. Launched a new $16M production line with complete hiring and training of

25+ associates.

. Forecast, planned, and managed purchase and control of raw materials and

spares inventories. Establish synchronized production with assembly and

supply chain. Reduced WIP and rework inventory by 81%.

. Reduced overall assembled unit cost by 45% over three years. Flex budget

in 2012 was favorable by 2%.

. Reduced total recordable incident rates (TRIR) to less than that of the

administrative office in 2012.

. Improved OEE for a 12-year-old paint line by 78% in a two-year effort

with minimum capital investment.

. Reduced downtime from 90+ minutes per day (two shifts) to less than 30

minutes per day.

. Produced Kaizens at a rate of 3.5 per employee in 2012; this improved

employee engagement.

. Maintained all documentation for ISO compliance; had no findings in 2011-

2013 audits and recertification.

March - August 2005 Haden Prism (Jeep Plant in Toledo) Auburn Hills,

Michigan

Senior Plant Engineer

. Played a key role in the final construction and setup of new Jeep paint

shop and finishing facility.

. Provided process equipment engineering and interfaced with suppliers and

contractors.

September 2002 - March 2005 Decostar Industries Carrollton, Georgia

A division of Decoma / Magna, a Tier 1 supplier of fascias and plastic body

parts for Mercedes Benz and BMW.

Facilities Manager

. Recruited before ground breaking to plan, schedule, and manage site

construction, startup activities, closing of contracts, and launch

support for this 350K SF, 30-acre, $100M plant.

. Engineered, selected, and installed process equipment - paint, injection

molding, power distribution, gas piping, fire protection, utilities,

infrastructure, supporting systems, and a state-of-the-art HVAC system.

. Developed technical specifications and performance expectations for

process equipment.

. Sourced supplier and contractor quotations. Reviewed and negotiated

contracts.

. Ensured installation met all applicable standards, codes, and

regulations.

. Communicated with relevant government and regulatory agencies to prepare,

review, and obtain approval for completion and operating permits, SWPPP,

and Title V Air Permit (initial and revised), etc.

. Prepared and presented justification and payback calculations for

corporate approval of funds.

. Planned equipment service, maintenance, modification, and utility usage.

. Set-up and maintained building security, janitorial services, cafeteria,

offices, infrastructure, computer room, facility grounds, and support

equipment and day-to-day operation and functioning of the plant.

. Developed operating procedures, contingency plans for equipment failure

and accident / emergency response.

. Developed Process Failure Mode Effects Analysis (PFMEA).

. Designed material flow and setup warehouse and sub assembly areas and

part flow.

May 1995 - September 2002 Haden Auburn Hills, Michigan

Haden was an ISO 9000 Tier 1 automotive supplier of construction,

engineering, and waste disposal services.

Lead Project Engineer / Site Contracts Manager / Project Manager

. Served as project engineer or lead engineer on 20+ industrial

construction, expansion, and modification projects ranging from $2M to

$100M+ for companies like Ford, GM, Toyota, Chrysler, AAM, GAZ, NUMMI,

and Boeing.

. Projects included building and structural work, pre-treatment and e-coat

systems, wet and powder paint booths, robotic application, paint

circulation and delivery systems, ovens, wastewater and sludge systems,

HVAC systems, RTO / VOC abatement systems, dry compressed air systems,

conveyors, chilled water systems, and steam piping.

. Provide technical and personal support and leadership to the design,

manufacturing, installation, and start-up teams consisting of designers;

mechanical, electrical and controls engineers; and construction teams.

. Provided project engineering, design and engineering calculations, and

equipment sizing and selection.

. Develop equipment and contract specifications, scopes of work, and RFQ's

for purchased equipment and contracts. Performed technical comparison of

proposals and obtained approvals.

. Coordinated project with customers, subcontractors, and suppliers.

Reviewed customer specs and translated them into RFQ for competitive

bidding. Sourced supplier and contractor quotations. Evaluated and

negotiated contracts.

. Provided hands-on construction management and startup.

. Solved technical problems at new and existing plants and presented

reports.

. Followed UBC, NFPA, OSHA, EPA, SMACNA, and ASHRAE codes and

recommendations.

. Assisted in site management of two $100M projects - NUMMI 1998-1999 and

TMMI 2001-2002.

Education, Professional Development and Skills

M.B.A., Management State University of West Georgia Carrolton, Georgia

B.E., Mechanical Engineering University of Engineering and Technology

(UET) Lahore, Punjab

Professional Development

. Post-graduate business management courses Oakland University

Rochester, Michigan

. Basics of PLC programing - Rockwell Automation, Michigan

. Leadership Courses; Building trust, Building Trust as a leader,

Decisiveness, Managing Conflict, Recognizing and managing conflict.

. Safety; Accident Investigation, OSHA Class for Management, LOTO.

. CTPAT General Awareness Certification.

. Dynamic 5-S and Visual Factory

. Essentials of Interviewing and Hiring (5 different in depth courses)

. Employee Development and Retention (multiple courses); Retaining Top

Performers, Retaining your Talent pool, Performance Appraisal and

Talent Management, Employee Engagement, Train the trainer..

. General Export Knowledge and Risk Certification

. Getting results without authority; Building relationships and

credibility.

. HIPA (Multiple courses)

. Legal; Legal & Effective Interviews, Legal Responsibilities,

Preventing Sexual Harassment

. Managing workforce generations; working with a multi-generation team

. Resource Conservation recovery Act (RCRA) Certification

. Root Cause and Mistake Proofing

. Workplace Harassment for supervisors and managers Certification.

. Working with Japanese.

Skills / Glossary

5S Kaizen Key Performance Indicators (KPI)

Lean

5-Why Fishbone Analysis Man, Machine, Material, Method (4M)

Plan, Do, Check, Act (PDCA)

Injection Molding Acrylonitrile butadiene styrene (ABS)

ThermoPlastic Olefin (TPO)

Reaction Injection Molding (RIM) Sheet Molded Compound (SMC)

All Terrain Vehicles (ATV)

Autonomous Maintenance (AM) Production Part Approval Process (PPAP)

Change-Over Reduction

International Standards (ISO) Key Performance Indicators (KPI)

Standardized Work.

Overall Equipment Effectiveness (OEE) Total Productive Maintenance (TPM)

Just in Time (JIT)

Microsoft Office Suite, Microsoft Project SAP, Adaptive Planning, MP2

Lotus Notes

Regenerative Thermal Oxidizer (RTO) Volatile Organic Compounds (VOC)

Title V Air Permit

Environmental Protection Agency (EPA) Stormwater Pollution Prevention

Plan (SWPPP)

Uniform Building Code (UBC) National Fire Protection Association

(NFPA)

Total Recordable Incident Rate (TRIR) Occupational Safety and Health

Administration (OSHA)

Process Failure Mode Effects Analysis (PFMEA)

Sheet Metal and Air Conditioning Contractors' National Association (SMACNA)

American Society of Heating, Refrigerating and Air Conditioning Engineers

(ASHRAE)

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