USAMA ALI

Pir Kot P/O Ahmad Nagar Wazirabad

Email:usamaalicheema@yahoo.com
Mobile: +923429882168

Profile Summary:

Develop, evaluate, document, and improve manufacturing methods and processes through Lean
techniques and Kaizen Events. Analyze and reengineer production layouts, designing and
implementing efficiency and quality improvement projects across production lines. Proficient in Visio,
Solid-Works, AutoCAD, Word, Excel, PowerPoint, Outstanding communication, problem-solving, and
relationship-management skills.

WORK EXPERIENCE
Forward Group (Pvt.) Ltd. Sialkot
A.M ME&MI (Industrial Engineer)
(Jan-2018 to Continue)
Implementing I.E functions

• Reduce changeover time from 180 minutes to 130 minutes by eliminating the NVA time.
• Prepare operation bulletin of new bags of FW19 and SS20.
• Plan layout of machines in accordance to new bag stitching and Line Balancing according to GSD.
• Identify and remove bottleneck process for smooth production.
• Calculating SAM by using GSD, Establishing stitching targets, enhancing efficiency of sewing lines.
• Method improvement by keeping in view the best possible ergonomics.
• Implementation of principle of motion economy.
• Designing sewing machine templates for better utilization of machines.
• Prepared Process Flow Charts, SOPs, Manufacturing control plan.
• Kaizen activity on monthly basis to improve manufacturing process.
• Preparing and updating visual management board on monthly basis.
• Preparing monthly reports of efficiency, forecast efficiency%, changeover, kaizen, downtime.

Re Engineering Project
NTN Layout & One Piece Flow

• Change stitching line layout from Traditional to face to face layout (Reduce width of
stitching line from 14 ft. to 8 ft.)
• Reduced WIP in the stitching line by 60%.
Kaizen Projects

o Sewing Machine Template

• Enhance production & quality by designing and implementation sewing machine template on
auto-sewing machine.

o Fabric spreading end bits

• Reduce fabric waste in cutting section during spreading & save $1144/season.

6S Implementation
• Conduct 6S Training for new inducted stitching Operator from Factory training School.
• Weekly 6S Audit and sharing score to everyone to create lean culture in the company.
• Operation Standardization by using GSD (General Sewing Data)

• Observing gap in Existing Sewing Method in Comparison with GSD method.

• Guide and coach operators to follow Standardized operation.

SMV Calculation.
• Got training from GSD Certified Trainer.
• Developed an Excel sheet to calculate GSD based SMVs of new bags.

Darson Industries (PVT) LTD Wazirabad.

MTO (Quality)
( June 2011 to August 2013)
Job Responsibilities:
▪ To identify and solve problems in design and manufacturing
▪ To insure that product dimensions, color and strength is according to the specifications
▪ To carry out inspection and checking on site to insure that all activities are as per approved
methods and test plan
▪ To report QA manager about the quality related problems on daily basis
▪ To conduct Cause and Effect Analysis in order to eliminate the causes of detected
nonconformities
▪ To train workers and supervisors about quality control procedures
▪ To identify 7-Wastes in the process and recommend necessary actions to remove them.
EDUCATION
2013-2017 MS Industrial Engineering and Management 3.72CGPA
2007-2011 B.Sc. Industrial and Manufacturing Engineering 3.26 CGPA

Main Module include:

✓ Manufacturing (Manufacturing and Machining Processes, Computer Integrated
manufacturing, Mechanics of Materials, Physical Metallurgy and Machine Design).
✓ Management (Total Quality Management, Statistical Quality and Process Control,
Lean Six Sigma, Systems and Standards (ISO 9001:2008) and Engineering
Management)

2005-2007 (Intermediate) National Science College, Gujranwala. 76.5 %

2003-2005 (Matric) Board of Intermediate and Secondary Education, Gujranwala. 80 %

PERSONAL PARTICULARS
Father’s Name: Safdar Ali

Date of Birth: November 21, 1992

Gender: Male

CNIC No: 34104-3700754-3

Domicile: Punjab

Marital Status: Single

REFERENCE
Reference can be furnished on demand.