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Altaf Khan (205 views)

Leader of Progress and Improvements

Sr.Mechanical Engineer

General Information

  • Slogan Leader of Progress and Improvements
  • Language English, Urdu, Arabic and Punjabi
  • Highest Degree Level Bachelors in Industrial Engineering & Management
  • Total Years of Experience 11
  • Expected Job Level Sr.Mechanical Engineer

BRIEF ON MY PROFESSIONAL EXPERIENCE AND ACHIEVEMENTS:
1. I am an Industrial Engineer who graduated in December 2011. I have 11-Years’ experience working on various variety of projects within the following types of manufacturing industries in Pakistan as well as in Saudi Arabia. However, I have performed different roles/duties during my career which includes QA/QC, Design, Production, Lead Project Engineer, and Manager QC.
a. Boiler Manufacturing, b. HVAC Manufacturing, c. EPC Company, d. Naval Shipbuilding

2. Furthermore, I have a thorough knowledge of ASME, ISO, API, BV Rules, TL Rules, and IACS standards along with 14x Technical, Safety, and Managerial Certifications which adds value to my competency and experience. The aforementioned traits make me a competent person for performing the assigned tasks for the manufacturing industry that seeks rapid progress and improvement.

3. Presently, I am working as a Deputy Manager-Ship Machinery Outfit since September 2021. During 01xYear Tenure of Working, I have been appreciated 03xtimes by Top Management for the following major improvements in work processes:
a. Keeping in view, the issues experienced by the QC Department in the qualification of welding procedures. I have requested additional responsibilities from management for resolving long-term ongoing issues of 40 x PQR Qualifications for different types of ship materials and accomplished the same within 08x Months. Special Incentive was awarded for this major achievement.
(Attached Letter of Special Incentive as Annex-A).

b. Due to the higher rate of failure in welding of pipes, I have trained QC Inspectors and production fitters for pipe fit up as per BV/TL Rules and ASME B31.3 standard. Moreover, also performed random visits to check the quality of shops. Furthermore, I have prepared and provided the pictorial instruction manual for fit-up and distributed it among the team.
(Reference will be provided on demand)
c. Major rework was carried out on Vendor processed Galvanized and Pickled pipes which were controlled through training QC/ production teams and revised technical terms & conditions of the contract to prevent the recurring quality issues that lead to rework by production.
(Reference will be provided on demand)
d. I have prepared a brief on “REWORK IN SHIPYARDS” along with remedial actions and the same has been forwarded to MD as a recommendation.
(Reference will be provided on demand)
4. Lead Project Engineer in (EDCVCM) plant expansion project of Engro Polymer & Chemicals Port Qasim, Karachi from Jan 2020 till July-2021 in which I have supervised complete Manufacturing of (Bolted) Steel Structures (Approx.1800 Tons), Plant Piping (Approx.24000 Dia. Inches) along with QA/QC documentation & record keeping work. Moreover, I have prepared cutting plans, B.O.M, erection drawings on AUTOCAD, QC Procedures & Forms Furthermore, repair of 04xshell tube heat exchangers has been performed. I have also participated in meeting
with the client to understand and meet their requirements. Following are major improvements in the above-mentioned project:
a. Reduced the wastage of structural material by preparing a cutting plan in excel sheets as per actual sizes. Leftover material was also being maintained and the same was consumed in the successor projects.
b. Steel (bolted) structure preliminary layout has been carried out in a workshop in order to avoid any issue during installation at the site.
c. For eliminating leakage during hydro-testing of high-pressure hydrogen reactor piping system suggested/implemented calibrated torque wrenches with set torque values as per the standard chart for uniform tightening of bolts around flanges.
d. Responded positively to the NCRs created by the client and addressed/satisfied through preventive actions, also provided standard references for closure.
e. Maintained record of scrap material and also assigned part number for traceability.
5. Production Engineer for the assembly line of HVAC Systems along with Electrical Control Box Assembly i.e. AHU, Chillers, Package Units, Mobile Air-Conditioners for ARAMCO, SECECO, Royal Commission, King Fahad University Hospital, Makkah-Medina project, etc. from May-2015 to July-2019, in Dammam, Saudi Arabia. I was responsible to prepare the production plan as per available resources with reference to the master production schedule. I have managed/supervised the complete assembly, and testing of the HVAC Systems along with research and development. Besides production, I was an active member of the safety & quality committee for improving the safety and quality of products by analyzing the customer complaints data
6. QA/QC Engineer for the boilers manufacturing (including Fire Tube Boilers, Water Tube Boilers, and Waste Heat Recovery Boilers) in Gresham’s Eastern (Pvt.) Ltd, Karachi, Pakistan where I have performed stage-wise inspections in liaison with Third Party Inspection Agency. Developed/updated new procedures for the processes i.e. Grit blasting & Painting, WPS, PQR, Hydro testing, etc. Cleared/justified technical queries through applicable standards/codes and best engineering practices. Adhered to a safe and quality work environment. Prepared Jigs and Fixtures for inspection work.
7. Looking forward to the interview call where we can discuss more the work that how I can benefit the organization through my vast experience and knowledge. The above-said information is true to the best of my knowledge and references will be submitted on demand.

Education

2011
Dawood University of Engineering & Technology Bachelor in Industrial Engineering & Management

Completed Subject Degree in December 2011 with 77% Percentage with majors in Mechanical, Manufacturing, Maintenance, Materials, Production, and Project Management.


Work Experience

01-09-2021(Present)
KARACHI SHIPYARD & ENGINEERING WORKS Deputy Manager (Machinery & Outfitting),PQR Qualification

·        Understanding the Shipbuilding scope of work and special contract requirements.
·        Ensuring adherence to the mutually agreed Inspection Test Plan, Drawings, and applicable Rules.
·        Conducting daily meetings with the QC team for monitoring and completion of assigned tasks.
·        Preparing Daily, Weekly, and Monthly QC activities progress reports.
·        Issuance of Observation and Non-CompliancernReports, following up for corrective action & closure.
·        Preparation/Modification of QC Procedures to meet the standard requirements.
·        Review of WPS, PQR test results for shipbuilding (various) material, as per Rule/Class requirement.
·        Understanding/resolving Class SurveyorrnTechnical queries on time.
·        Continuous improvement through training, development, and team motivation.
·        Training production technicians to avoid daily recurring QC issues through One Point Lesson.
·        Record keeping of NCR Logs, Class Surveyorrncomments logs maintained in the file.
·        Introducing QC Inspection Tools for capacity building, calibration, and maintenance of Non-Ops tools.

 ACHIEVEMENTSrnIN SHIPYARD & ENGG.WORKS LTD, KARACHI

·      Undertaken 48x PQR Qualification tests for shipbuilding material i.e. DH36, Normal Strength, CuNiFe, Aluminum, SS, and cast materials. Rewarded by Top Management with incentive.
·        Destructive Testing/Verification for shipbuilding materials with Class Surveyor as per Class Rules.
·        Implemented One Point Lesson Technique in order to control repetitive Quality Issues.
·        Highlighted non-standard practices to management and suggested applicable solutions for pickling/galvanizing 


06-01-2020 TO 30-06-2021
SURIA ENGINEERING, KARACHI Lead Project Engineer

·        Understanding Project Scope of Work and Project Timeline for planning and monitoring.

·        Preparing daily, weekly, and monthly progress monitoring reports.

·        Preparing fabrication drawings with details for smooth production.

·        Preparing structural members and plate connections cutting plan along with the bill of material.

·        Inspection of mock-up assembly of structures.

·        Arranging customer meetings for technical queries and special requirements.

·        Preparing procedures for process i.e. Dish End Manufacturing, Heat Treatment, Sand Blasting, Painting.

·        Ensuring standards compliance as per Inspection Test Plan.

·        Arranging customer inspection as agreed in Inspection Test Plan.

·        Suggestion/selection of QC Inspection Tools for Improving Quality and Customer Satisfaction.

·        Responding to technical queries from customers with reference to standards/codes.   

 LIST OF PROJECTS 

·        Achieved on-time completion of following projects while performing duties as Lead Project Engineer.

1-   Engro Polymer & Chemicals Plant Expansionrn(Port Qasim, Karachi)              

Project Duration: Jan 2020 to Jul-2021

Scope: Fabrication of (Bolted) Steel Structurern(18000+Tons), Repair of Imported Old Structure(40 Tons), Piping Fabrication and Installation (2400 Dia. Inch) at Plant, Fabrication/Repair of03x Heat Exchangers of different capacities.

2-   ACT Polyols (Nooriabad, Karachi).

Project Duration: Jun 2019 to Mar-2021

Scope: Complete Fabrication/Installation of Sorbitol & Glucose Plant, steel structure, plant piping, and complete equipment i.e. 01xHydrogen Generator, 03x Hydrogen Reactors, Glucose, and  Sorbitol Plant Machinery.

3-   PSO Terminal-1, Keamari, Karachi.

Project Duration: Janrn2021 to Mar-2021

Scope: Repair and installation of damaged piping of Petrol Terminal from Port Jetty to Terminal approx.25 KM.

4-   02x Incinerator (Capacity: 50 KG/Hr.) manufacturing for PNS Shifa Hospital.

5-   Vertical Shell Tube Heat Exchanger manufacturing for Engro Polymer & Chemicals.

6-   Repairing of 03x shell tube type heat exchangers (TT-306, TT-307, and CN-2F) for Engro Polymer & Chemicals).


10-05-2015 TO 30-06-2019
ALZAMIL CENTRAL AIRCONDITIONERS-DAMMAM, SAUDI ARABIA PRODUCTION ENGINEER

·        Understanding Scope of Work, Deviation Reports, special Requirements, and Drawings.

·        Following the “Master Production Schedule” and preparing a production plan to meet the required production by utilizing available resources.

·        Maintaining an updated record of material shortages with the expected time of arrival.

·        Participating in Daily Production Meetings withrnPlanning, Fabrication, and QC teams to meet requirements.

·        Prioritizing Units completion other than Master Production Schedule.

·        Responding to customer complaints, and suggesting preventive actions to control issues.

·        Conducting Vendor Sample Evaluation test to check the feasibility of assembly.

·        Preparing daily, weekly, and monthly ProductionrnMonitoring/Performance Reports along with Downtime Reports. Assisting management with preventive actions required to meet the deadlines.

·        Repairing of HVAC Systems as per provided work order sheets.

·        Application of Lean Manufacturing and KaizenrnTechniques for continuous improvements.

·        Ensuring the safety of equipment, property, and manpower and informing the safety officer in case of any findings.

·        Assembly of electrical control boxes i.e. DOLrnStarters, Star Delta Connections for Chillers, AHU, and Package Units.

ACHIEVEMENTS IN ALZAMIL AIR CONDITIONERS

·        Reduced wire scrap by 20% while using small length wires for smaller product group units.

·        Reduced recurring design-related issues through cooperation with the design office.

·        Highlighted/reduced major recurring reworks and their impact on production efficiency.

·        Improved teamwork culture through counseling, and motivation resulting in productivity improvement of 25%.

·        Manufactured multiple products in assembly lines by avoiding the culture of one product type production.


01-04-2012 TO 30-04-2015
GRESHAM’S EASTERN (PVT.)LTD PROJECT ENGINEER

·        To Manage Plans and Schedules to Effectively Organize the Work Shop Fabrication Activities.

·        Tornprepare B.O.Q, Plan for Resources such as Man Power/ Material to Meet Project Requirements

·        To Prepare Weld Maps and Weld Matrix from Isometric Drawings

·        Safe Execution of Gas Cutting, Grinding, SMAW & GTAW

·        To Participate in Weekly Meetings with the Workshop Manager / Operations Manager and keep them informed of progress

·        To Ensure Proper Documentation required for the Completion of Work as per ISO 9001rn& Gain approval from the Q.C Department

·        To ensure that the Safety Regulations have adhered.

·        Monitoring of Post Weld Heat Treatment of Annealing Furnace Operation.

MAJORrnIMPROVEMENTS 

·        Application of Japanese Production System (5S, Kaizen, Jidhoka)rn

·        Provide in-house training to the Employees to improve productivity

·        Emphasized meeting the Work and Safety Standards with less wastage.

·        Made Jigs and Fixtures.


Summary of Skills

Production/Manufacturing
90%
Estimation & Invoicing
85%
Steel Structure Fabrication
100%
Pipe Fabrication
100%
Bill of Material Preparation
100%
Exchanger Manufacturing
95%
AUTOCAD
75%
1-ASMEStandards, 2-IACS Shipbuilding Society, 3- API Codes, 4-TEMA Standard, 5-ISO/BSEN Standards, 6-BV/TL Rules
90%
Supervisory Skills
95%
Breaking the Barriers
90%
Key Performance Indicators
80%
IOSH-Managing Safely
90%
ERP/SAP End-User
90%
Machinery Installation
100%
QA/QC
90%

AWARDS

INCENTIVE FOR TAKING INITIATIVE OF 40x PQR QUALIFICATIONS W.R.T SHIPBUILDING MATERIALS (2021 )

Keeping in view, the issues/challenges experienced by the QCrnDepartment in the qualification of welding procedures. I have requestedrnadditional responsibilities from management for resolving long-term ongoingrnissues of 40 x PQR Qualifications for different types of ship materials andrnaccomplished the same within 08x Months. Special Incentive was awarded for thisrnmajor achievement.


Appreciation from Top Management for Training Pipe Fitters also Prepared Pictorial Guidelines (2022 )

Due to the higher rate of failure in welding of pipes,rnI have trained QC Inspectors and production fitters for pipe fit-up as perrnBV/TL Rules and ASME B31.3 standard. Moreover, also performed random visits torncheck the quality of shops. Furthermore, I have prepared and provided thernpictorial instruction manual for fit-up and distributed it among the team.


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