Kafayat Ullah
Hillcrest,New Zealand
Summary
Dynamic Manufacturing Coordinator with a proven track record at FrieslandCampina Engro Pakistan, driving over 10% OEE improvement through innovative lean methodologies. Skilled in continuous improvement and data analysis, I excel in stakeholder engagement and team leadership, delivering impactful results in operational excellence and cost reduction strategies.
Overview
15
15
years of professional experience
Work History
Manufacturing Coordinator
FrieslandCampina Engro Pakistan Limited
Pakistan
12.2021 - 02.2025
- As Maintenance Coordinator, I served as a change agent for Continuous Improvement by introducing PDCA methodology, Go Gemba practices, and the Equipment Ownership model across the site. I led the deployment of the OWOW lean system, achieving over 10% OEE improvement by extending production runs and other initiatives. Through structured target setting, audits, and deep dive exercises, I delivered 3% OEE improvement, 2% loss reduction, and 5% controllable cost savings. I introduced Tier Meeting structures and problem-solving tools on the shop floor to support waste reduction and performance gains. I led CI programs like WCOM, 5S, Kaizen, and launched the AM Pillar in Dairy, Ice Cream, and Utilities to reduce routine stoppages by 5% annually. I also developed the Site E&T Capability Matrix under the 70-20-10 framework and coordinated closely between the Site Leadership Team and Director Manufacturing.
Continuous Improvement Specialist
FrieslandCampina Engro Pakistan
Sahiwal, Pakistan
07.2019 - 12.2021
- As a Continuous Improvement Specialist, I implemented CI programs such as WCOM, Autonomous Management, 5S, Kaizen, and PCS work sessions. I led Dairy and Ice Cream work streams focused on OEE, labor, productivity, loss reduction, and fixed cost savings. I launched Kaizen initiatives across departments, trained operators, and executed improvement ideas. I spearheaded capability development through TNA-based training and led the department in various audits (ISO, One Audit, Halal). I supported sustainability and HSE programs, conducted risk assessments and RCA, and optimized maintenance workforce efficiency through value-added analysis. I also improved team capability through skill gap analysis and targeted projects.
Maintenance Lead Dairy F&P
FrieslandCampina Engro Pakistan
Sahiwal, Pakistan
06.2013 - 07.2019
- I develop and implement PM plans based on OEM guidelines and engineering best practices. I enhance reliability through CBM and RCA techniques, achieving a 17% improvement in MTBF and a 27% reduction in breakdown costs, along with a 20% reduction in unplanned stops through data-driven PM optimization. I plan and execute TPMS for all dairy filling and packaging machines, ensuring timely servicing every 1000 running hours and maintaining accurate TPMS checklists. I manage spare parts inventory aligned with planned maintenance and have successfully installed TB22, A3 Speed, and capper machines across various packaging lines.
Maintenance Coordinator
Philip Morris International
Pakistan
05.2011 - 06.2013
- As Maintenance Coordinator in the secondary department, I led preventive and corrective maintenance activities for all filling and packing machines. I was responsible for weekly and monthly PM schedules and developed PM plans based on OEM recommendations and engineering standards. My role included managing field maintenance jobs, manpower, inventory, and work permits. I also oversaw major overhauls of machinery and stationary equipment such as pumps, compressors, and heat exchangers, along with ensuring consistent daily preventive maintenance.
Maintenance Trainee
Fauji Fertilizer Company Limited (FFC)
Pakistan
06.2010 - 05.2011
- As a Maintenance Trainee, I completed 5 months of theoretical TTC training on mechanical equipment, including pumps, heat exchangers, valves, and compressors. I assisted in preventive and corrective maintenance of rotating and static equipment, supported troubleshooting, and participated in shutdown and turnaround activities involving inspection and overhauls. I ensured adherence to HSE protocols and SOPs, maintained detailed maintenance documentation, and collaborated with senior engineers to gain hands-on experience in general preventive maintenance.
Education
Master of Science - Mechanical Engineering
Comsats University Islamabad
01.2020
Bachelor of Technology - Mechanical (Hons)
The Islamia University of Bahawalpur
01.2015
Diploma - Mechanical Engineering
Govt College of Technology Sahiwal
01.2009
Skills
- Continuous improvement
- Lean manufacturing
- Operational excellence
- Process optimization
- Equipment maintenance
- Preventive maintenance
- Data analysis
- Stakeholder engagement
- Problem solving
- Inventory management
- Regulatory compliance
- Training development
- Project management
- Team leadership
- ISO standards
- Cost reduction strategies
- Industrial hygiene
- Reliability analysis
- Performance improvement
- Quality control guidelines
- Process integration
- Manufacturing processes
- Materials estimation
- Drawing interpretation
- Emergency response management
- Preventive maintenance planning
- Production scheduling
- Program management
Hobbies and Interests
Volley ball
Values And Knowledge
I am a results-driven professional with a strong focus on innovation, collaboration, and continuous improvement in manufacturing and engineering. I lead initiatives that integrate cutting-edge technologies, foster inclusive and high-performing teams, and drive sustainable, socially responsible practices aligned with New Zealand’s values. With expertise in systems like Tenforce (DMS, CAPA, IR), Decibel (Attendance), and Microsoft Office, I ensure operational efficiency through data analysis, audits, and compliance. I excel in project management, stakeholder engagement, and process optimization, consistently promoting professional growth, clear communication, and a culture of excellence, accountability, and collective success.
Work Rights
Full rights to work in New Zealand for 3 years.
Timeline
Manufacturing Coordinator
FrieslandCampina Engro Pakistan Limited
12.2021 - 02.2025
Continuous Improvement Specialist
FrieslandCampina Engro Pakistan
07.2019 - 12.2021
Maintenance Lead Dairy F&P
FrieslandCampina Engro Pakistan
06.2013 - 07.2019
Maintenance Coordinator
Philip Morris International
05.2011 - 06.2013
Maintenance Trainee
Fauji Fertilizer Company Limited (FFC)
06.2010 - 05.2011
Master of Science - Mechanical Engineering
Comsats University Islamabad
Bachelor of Technology - Mechanical (Hons)
The Islamia University of Bahawalpur
Diploma - Mechanical Engineering
Govt College of Technology Sahiwal
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