Alumni Profiles

Waqas Ali

Organization Information

To date, MISIL has gradually taken leading position in the production of high-performance structural steel and high-quality long products. Among them, the constructional Girder Beam“I Beam” wins the honor of “Best Brand of Pakistan”; hi-tech industrial complexes , to infrastructural projects – power & energy, roads & bridges, dams/generation & distribution networks, high rises to economic housing solutions have won great fame both in domestic as well international market. The well-defined streamlined work process of MISIL has enabled it to quickly process orders within the stipulated period.

Describe the work that you do in your role

? Supervise, Direct and monitor the replenishment planning of inventory items to meet maintenance requirement, safety stock, improve efficiency and product availability in Inventory Store / Warehouse.
? Manage the entire process in the material planning and supply chain activities, Inventory Control, forecast analysis, in bond Logistics, distribution / dispatches, ensuring effectively functioning process to avoid costly delays and lost opportunities (Sale
Rs. 22,000 Million FY-2018).
? Formulate & develop supply chain strategies to ensure smooth supply chain operations. Manage the quality, quantity, Cost and efficiency of the movement and storage of products.
? Co-ordinate and oversea the complete logistic cycle of Finished and by products integrating the flow of products with OTIF Objectives.
? Efficiently review and introduce process improvements in the supply chain and identify the problems with possible alternate solutions.
? Reduced financial burden on inventory by synchronizing planning and procurement functions, reducing lead times, redefining order lots and inventory levels.
? By implementing lean Six Sigma methodology, Continuous improvement approaches, save more than Rs. 20 Million/ year and improve yield of Finished Products.
? Negotiate contracts to achieve cost effective outcomes for the business, applying KPIs to gauge maximum efficiency.
? Conduct regular, spot check as per physical cycle counting principle to Improve, achieve and maintain physical count accuracy of more than worth of Rs. 700 Million.
? Efficiently supervised implementation of ERP Modules of Inventory, Procurement, Production and Master product data in Microsoft Dynamics AX 2012.
? Planning routs and load schedule for multi drop deliveries and minimize transportation cost / liter of fuel.
? Lead through coaching, mentoring and provide guidance to staff (275+ employees) and highlight their capabilities to enhance interpersonal skills.

Indicate previous experience and/or areas of career proficiency/achievenments

Inventory Control Officer
Ingredion Incorporated USA. Jul 2007 – Feb 2017
(Pakistan Plant: Rafhan Maize Products Co., Ltd, Faisalabad)

Assistant Manager Materials Dec 2004 – Jul 2007
Masood Textile Mills Limited, Faisalabad

Deputy Management Representative
Jun 2002 – Dec 2004
ZahidJee Textile Mills Limited, Faisalabad

Developing Supply & Stock strategies: Achieve 0% Sale & Production loss.
Sales Forecast Accuracy: From 81% to 93%
Production Planning Vs. actual Accuracy: From 84% to 96%
Supervise 31+ cost-saving initiatives and Lean Six Sigma projects and save millions.
Manage Despatches more than 125,000 Tons annually.
Optimizing inventory: Reduce investment, Increase WC & Save Rs. 150 Million
Warehousing techniques/layouts/procedures: Reduce waiting time from 45 to 23 Minutes
Lead time Reduction: 45 Days to 15 Days
Reviewing slow-moving & dead items: Reduce financial burden 18% on Inventory
OTIF: Back or Backorder Frequency / month: 11% to 0%
Designing & Implementing Supply planning strategies (MTS / MTO/JIT)
International exposure to implement SAP (MM & PP) in Five Production plants & finalize SAP Business BluePrint, GAP Analysis
Implementing VMI: Plan to purchase Raw & Packing materials of Rs.43 Million/month approx.
Annual / cycle physical count and: Improve Stock Accuracy 97% to 99.93%

Describe your success in your professional life and achievements

Young, Energetic, Passionate & Proactive Business graduate with Certified Supply Chain Professional (CSCP-APICS-USA), Certified Lean Six Sigma Green Belt, M.S in Supply Chain and pragmatic business leader equipped with more than 17 years of success in major multinational and national companies. Background encompasses Supply chain, Production Planning, Inventory Control, Demand & Forecasting, Warehousing & Stores, Lean Six Sigma, ERP Implementations and delivering training, with specific expertise identifying & implementing solutions to generate multi million savings, raise ongoing growth, and realize highly efficient operations. Offer record of achievement improving processes and managing complex projects by training & coaching the employees to on-time and on-budget completion. Confidently build strategic business alliances to promote growth and sustainability.


Rationalizing Inventory by Implementation of Supply Chain Strategies

? Developed & implemented the company’s Production, Supply & Stock strategy with the aim of customer service level, generating savings, controlling cost with in budgetary limits, rationalizing inventory & maximizing available working capital.

? Developing planning strategies by implementing RCCP (Rough cut capacity planning) and Long term planning for 18 months of Forecast and procurement planning of Raw Materials, Packing (Rs. 13 Billion)

Improving efficiency in waiting time of material issuance

? By designing & implementing Supply planning strategies (MTS / MTO, make to stock/ order) reduce waiting time and improve service level.

Reduction in Lead time of Procurement Process
? Using Lean six sigma techniques reduce significant lead time (45 days to 15 days), reduction in stock outs, increase in inventory turnover and improve working capital

Lean Manufacturing
? Identify wastages of process and provide best alternate solution to increase production efficiency by reducing wastage and save Rs. 27 Million / year.

ERP Implementation on different plants (SAP, Oracle & Microsoft Dynamics AX –2000)

? International experience of implementing SAP (MM & PP Modules) as a team member in different countries of Ingerdion. Exposure to work with the team of Thailand, Korea, Germany, USA, Canada etc.

? Part of team successfully implemented Oracle & Microsoft Dynamics at different production plants, Inventory & Material Planning, Stores & Warehouse.

Quality improvements of Finished Products

? Identifying the root cause analysis, Fish bone, SIPOC diagram, Statistical analysis by DMAIC (Define, Measure, Analyze, Improve and Control phases) of Lean Six Sigma and improve 1st pass of Finished Goods from 34% to 88% Approximately.

5 S Implementation in Inventory Stores
? Trained the staff and achieve the goals in just 3 months of 5S (Sort, Set in Order, Shine, Standardized & Sustain) and received incentives (Cash prizes) for team by finding record or material within 30 seconds.

Reduction in Investment & Carrying cost
? By reviewing slow moving & dead items, reduce financial burden 19% of Inventories in current year and saving interest, taxes, insurance paid on inventory and reduce warehouse space, time & personals as well.
? To avoid excess inventory and save all related costs (storage, carrying, handling cost etc.) by less use of company’s capital, developed and implemented VMI (Vendor managed inventory) program to purchase Raw & Packing materials of amounting Rs.343 Million monthly.

Write your activities and achievement if you were member of any club or society in UMT?

I was not member.

What do you remember about your time in ILM / IMT /UMT?

That was good enough, very renowned names of Supply Chain were teaching us.