IJAZ UL HASAN
Kuala Lumpur,14
Summary
A high-impact Project Manager and Lean Coach with over 19 years of experience in the manufacturing sector, specializing in driving operational excellence and leading transformational projects. Expertise includes applying Lean Sigma methodologies to significantly enhance manufacturing operations, reduce waste, and increase productivity. A proven track record in applying lean principles to project management, driving operational efficiency, and achieving productivity improvements. Skilled in providing industry advice to business owners, facilitating strategic decisions, and implementing total productive maintenance and industrial engineering practices. Extensive experience in designing and delivering corporate training programs to upskill teams and drive organizational change. Diverse industry exposure includes Chemical Processing Plants, Textile & Clothing, Automotive, and other manufacturing industries. Successfully led large-scale projects, ensuring agile solutions while maintaining stringent quality standards. Extensive experience in consulting start-ups to establish their industrial plans from the ground up, ensuring a competitive edge, sustainability, and exponential growth.
Overview
19
19
years of professional experience
1
1
Certification
Work History
SME Consultant
Accenture
07.2023 - Current
- Core Team Member Trainings on Management Control & Reporting System
- Resource optimization is performed as workstream lead in the pool of consultants for the project in the Processing Plant
- Agile Supervisor Training for supervisory positions
- The project consists of phases named Conception and Implementation
- Each operation and function are analyzed deeply
- An internal team of change agents is formed and trained
- Work aids and scheduling developed at different sections to improve productivity and overall Equipment Effectiveness (OEE)
- Lean Manufacturing Tools implementation
- Cost at each point is tracked for times, resources, utilities, etc.
Manager Training & Consulting
Center for Business Solutions
10.2015 - 05.2023
- Conducting base line studies in SMEs and present proposals for their capacity building program
- To implement lean practices in manufacturing setups especially in textile, garment, auto parts and food & Beverage industry
- Corporate training on various subjects with the associated clients based on the needs assessment
- Supervising and conducting awareness and diploma programs
- Support SMEs in improving their marketing skills
- Lean Practitioner in following tools: 5S Housekeeping, Re-Engineering Layouts, Lead Time reduction, Total Productive Maintenance, Process Control through eliminating Muda (Seven wastes), Improving Quality, Inventory Management, Implementing one piece flow, Scheduled Kaizen activities, Implementing Industrial Engineering tools (Work scheduling & Line Balancing, etc)
SCORE Trainer
Leverage Limited
09.2022 - 01.2023
- SCORE Workplace Cooperation & Gender Equality in partner factory in Punjab (Client: Ayesha Spinning)
- Conducted baseline assessment and Training of enterprise improvement team (EIT)
- Implementation of Gender Equality module
- Cost Saving while practicing workplace cooperation and Lean Tools
- Development of women development forum in factory to address issues associated with women
- Participation of females in all committees
- Develop yearly Training calendar and initiate to conduct training
- Hire females to attain gender balance in different sections in the factory.
FIT Facilitator
International Labour Organization
10.2021 - 03.2022
- FIT is a self-facilitated, activity-based learning approach designed to support garment manufacturers to improve productivity, competitiveness and working conditions by upgrading production systems and factory practices
- In pilot program in Karachi, following four modules are facilitated in selected garment factory in the project
- Setting up Factory for FIT
- Problem Solving
- Line Planning sewing room operations
- Critical Thinking and reasoning in the factories
- Being facilitator in the enterprise, a mechanism is developed to adopt best practices observed while read out sessions in the modules
- Following key practices are adopted and in reviewing process
- Development of meeting mechanics and efficiency measures
- Meeting cards are developed
- Sewing line check list is developed to ensure pre-requisite are ready for day new style in the line
- It helped in achieving first day efficiency from 20 - 28%.
Independent Consulting Partner (ICP)
T.A. Cook
10.2020 - 01.2022
- Being part of a pool of consultants with 'T.A Cook Consultants (Hon Kong) Co Ltd' for the project in a Chemical Processing Plant (Pakistan), resource optimization is performed
- The project consists of three phases: Analysis, Conception, and Implementation
- Each operation and function are analyzed deeply
- An internal team of change agents is formed and trained
- Work aids and scheduling developed at different sections to improve productivity and overall Equipment Effectiveness (OEE)
- Cost at each point is tracked concerning times, resources, utilities, etc.
Productivity Trainer & Consultant
Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH
06.2020 - 12.2020
- Assist to develop industrial regulatory framework for implementing industry environment management system
- Developed comprehensive industrial solid waste and wastewater management system
- Developed effective strategic industrial chemical management plan
- Sustainable water resource and recycling management for garment and textile industries
- Coordinate with related government officials, industry owner & expert and implementation agencies.
Lead Trainer (SCORE)
International Labour Organization
11.2018 - 09.2020
- Capacity Building of partner factories by implementing SCORE methodology & Techniques in Garment Factories
- Implementing Productivity & workplace cooperation tools
- Developing pilot areas
- SCORE Modules cover: Driving change in your business, Involving everybody through 5S, Empowering employees through better communication, Fair HR policies for better workforce management, Enhancing productivity, Measuring workplace improvements, Quality first, Safety and health at work - a platform for productivity, Productivity through cleaner production / Environment management.
Productivity Consultant, Social & Labor Standard in Textile & Garment Sector
Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH
10.2015 - 06.2017
- ISSSP Project (Oct 2015 - June 2016) SLSG Project (Aug 2016 - June 2017)
- GIZ's (German Society for International Cooperation) Short term consultancy for the labour standard and productivity component, setup of model lines in selected garment manufacturing units
- During assignment material handling has been improved from 70-80%
- Defect Rate reduced from 13% to 7% at end line
- Efficiency improved from 68% to 84% (at Home Textile & Garment Manufacturers)
- Finding Gaps in material flow and improve by re-engineering layout
- Conduct Training factory wide for implementing practices
- Implementing one piece flow
- Develop salary plus incentive models.
Assistant Manager Training & Consulting
National Productivity Organization, Ministry of industries, Government of Pakistan
11.2009 - 09.2015
- Provide Training & Consultancy to Small and Medium Enterprises for Continuous Process Improvement through implementing 5 'S', Industrial Engineering tools & techniques
- Developing quality management systems
- Multi tasking
- Total Productive Maintenance Implementation
- Organize and manage training for the individuals and industrial sector (SMEs and large sector organizations)
- Prepare training & consultancy project proposals for the process improvement of manufacturing setups
- Plan future activities (training/consultancy) for the development of industrial sectors
- Prepare and manage training budget.
Consultant
Chemonics International Inc
02.2013 - 09.2014
- USAID Firms Project - Lean Manufacturing and Productivity Improvement in Agriculture implements manufacturing sector with Value Chain Development department of USAID Firms Project
- Following lean activities were performed as consultant: Implementing 5S at production floor
- Highlighting MUDA (seven wastes) in production
- Improved material flow (material handling improved to 57%)
- Conduct training of Lean practices at all level
- Improved production with least absenteeism
- Improved standard minute value of production (from 120 min to 100 mins)
- Training at all level.
Lecturer
The University of Faisalabad
11.2008 - 11.2009
- Teaching following courses to textile engineering students: Industrial Engineering, Apparel Technology, Engineering Economy, Product Development, Anthropometry and Garment Construction
- Supervision and guidance to final year student's thesis/projects: Selected thesis topics include: Product Development practices in different Apparel Industries in Pakistan, Comparing different Apparel Production systems with respect to productivity and efficiency, Improvement of workplace arrangements for sewing operators to maximize production.
Project Trainee
TUSDEC
02.2008 - 10.2008
- Follow up Productivity improvement project at SMEs and Large Scale organizations
- Coordinate with consultants and TUSDEC and report about the initiatives taken by the consultants
- During the project assist the consultants by: Conducting Time and motion Study of the ongoing production
- Highlight Gaps in order to improve productivity and Quality
- Strengthening the Industrial Engineering team by training.
Industrial Engineer
Ali Murtaza Associates (pvt)
05.2007 - 02.2008
- I have worked as industrial Engineer in Ali Murtaza Associates (pvt) Ltd
- They are dealing in garment specially Bottoms
- During my Probation I got training from DCG (Dagher Consultancy Group) consultants about Work Study, Method Study Procedures and other IE techniques that are specially designed for sewn product industry like PMTS, GSD and SDM
- Achievement: Using all my Knowledge, Experience and job training I have made my own SDM (Sewing Data Management) software by using SDM codes (Microsoft Excel)
- My Job Responsibilities were as follows: To monitor and control training center activities
- To train machine operators according to standard motions (using SDM codes)
- SMV calculation for new order before sewing
- To do capacity and production study for production bottlenecks.
Asst Manager
Masood Textile Mills Ltd.
02.2005 - 03.2007
- I have more than two-year experience in Masood Textile Mills and I have been running the latest technology system Eton related to production & quality control in garment industry
- My responsibilities were as follows: Controlling sewing and quality process according to standard requirements
- Organizing manpower, material and their optimum utilization
- Analysis of production method & overcome bottleneck by proper line balancing
- Monitor quality status of all programs by season
- Management of production timelines, reviewing reports.
Education
M.Sc - Engineering Management
University of Engineering And Technology, Lahore
Lahore, Pakistan08.2011
BSc Engineering - Textile Engineering
National Textile University
Faisalabad, Pakistan12.2004
Skills
- Strong analytical skills
- Stakeholder Management
- Research and Development
- Training and mentoring
- Creative solutions
- Strategic Thinking
- Project restructuring
- Process Analysis
- Idea Development and Brainstorming
- Problem-solving aptitude
- Analytical Skills
- Task Prioritization
Websites
Certification
- Certified Lean Six Sigma Black Belt
- Scrum Master Certified (SMC)
- Certified SCORE trainer / consultant
Languages
English (Full Professional)
Personal Information
Title: Lean Manufacturing Coach l Sustainable Business Transformation I Six Sigma Black Belt I Certified SCORE Trainer l Certified SCRUM Master
Publications
- Implementation status of TQM Practices in Textile & Apparel
- Industrial Organization: case study
Timeline
SME Consultant
Accenture
07.2023 - Current
SCORE Trainer
Leverage Limited
09.2022 - 01.2023
FIT Facilitator
International Labour Organization
10.2021 - 03.2022
Independent Consulting Partner (ICP)
T.A. Cook
10.2020 - 01.2022
Productivity Trainer & Consultant
Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH
06.2020 - 12.2020
Lead Trainer (SCORE)
International Labour Organization
11.2018 - 09.2020
Manager Training & Consulting
Center for Business Solutions
10.2015 - 05.2023
Productivity Consultant, Social & Labor Standard in Textile & Garment Sector
Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH
10.2015 - 06.2017
Consultant
Chemonics International Inc
02.2013 - 09.2014
Assistant Manager Training & Consulting
National Productivity Organization, Ministry of industries, Government of Pakistan
11.2009 - 09.2015
Lecturer
The University of Faisalabad
11.2008 - 11.2009
Project Trainee
TUSDEC
02.2008 - 10.2008
Industrial Engineer
Ali Murtaza Associates (pvt)
05.2007 - 02.2008
Asst Manager
Masood Textile Mills Ltd.
02.2005 - 03.2007
M.Sc - Engineering Management
University of Engineering And Technology, Lahore
BSc Engineering - Textile Engineering
National Textile University
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