Akif Hussain

Senior manufacturing head with full operational and financial responsibility for a 16,800 sq. m PET packaging plant. Accountable for P&L performance, daily execution, modernization, cost of conversion, workforce capability, and long-term scalability. • Improved OEE from 55% to 65% through targeted loss elimination and performance discipline. • Reduced rejects to 1.5% in thermoforming and 3% in extrusion by stabilizing processes and strengthening capability. • Generated $1M in annual savings through waste reduction, labor optimization, and lower cost of conversion. • Led plant expansion and consolidation efforts to support higher throughput and streamlined operations. • Achieved full adoption of post-industrial recycling and embedded closed-loop practices. • Improved uptime by 15% by enforcing TPM-aligned maintenance discipline. • Reduced breakdown maintenance by 25% through reliability standards and targeted interventions. • Secured $0.5M yearly savings through supplier optimization and procurement governance. • Shortened new-product launch timelines by 20% through tighter R&D alignment. • Directed remote commissioning of Bandera extrusion line with rapid operational stabilization.

Rebuilt production discipline, streamlined shift structures, and advanced safety, process control, and technical capability across thermoforming, printing, and extrusion teams.

Led a large unionized PVC/HDPE extrusion operation, strengthening throughput, labor productivity, and process stability while embedding Lean behaviors across all shifts. • Raised productivity 335 → 480 lbs/labor hour by restructuring labor models and tightening line efficiency. • Cut scrap 14% → 9% by enforcing data-driven quality control and stabilizing process windows. • Reduced conversion cost by 3.5 cents/lb through precise material usage and yield improvement. • Delivered 30% efficiency gain through targeted layout redesign and flow optimization. • Reduced changeover time by 20% using structured SMED techniques. • Brought machine uptime to 85% through reinforced maintenance rhythms.

Directed operations across PVC, HDPE, PPR, and ABS extrusion and injection molding. Strengthened profitability by transitioning outsourced items to in-house production and redesigning process/maintenance systems. • Generated AED 5M annual profit through a complex 3 plant consolidation into one high-performing site. • Delivered AED 1M cost savings through budgeting rigor and engineered maintenance improvements. • Reduced fitting cost 30% & seal cost 40% via in-house production conversion and process standardization. • Increased fittings and seal sales by 15% through improved availability and cost competitiveness. • Eliminated 16 operators across four shifts by automating targeted processes without capacity loss. • Shifted maintenance to 70% PM vs 30% breakdown using SAP-driven planning. • Raised uptime to 85% through reliability-focused upgrades.

Led thermoforming and extrusion operations in a food-grade environment while enforcing strict quality, material control, and productivity systems. • Delivered $1.4M annual savings through automation, labor productivity and optimized material usage. • Raised productivity to 102% by tightening throughput, planning, and rapid-response problem solving. • Reduced waste to 2.5% via precise process control and quality rigor. • Passed KFC and A&W food-safety audits with clean compliance records. • Reduced quality complaints from 2.1 → 2.0 per 100M units.

• Led plant-wide process optimization and Lean Six Sigma deployment (5S, TPM, VSM, Kanban, DOE, FMEA), implementing SPC (Data-Mite) to stabilize operations and boost throughput. • Increased machine uptime by 20%, reduced scrap by 7%, achieved 100% regrind utilization, and cut changeover time from 8 to 5 hours. • Reduced overweight by 15% via gear pump integration and automated bagging (4 → 1 operator), lowering quality complaints by 10%.

• Provided hands-on technical leadership for daily production operations, resolving process, material, machine, and tooling issues while standardizing setup duration and quality controls. • Led a 20-member production team, performed time and motion studies, analyzed operational data, and implemented productivity improvements to consistently meet output and quality KPIs. • Enforced strict HSE compliance and optimized material flow coordination between setup teams, operators, and handlers to sustain uninterrupted production. • Reduced production scrap from 7% to 2% through root cause analysis, process stabilization, and setup standardization.

• Directed three shift supervisors to enforce production KPIs and quality systems, led daily performance reviews, upheld HSE compliance, and drove time-study–based changeover standardization through continuous improvement initiatives. • Strengthened workforce capability by leading technical training programs and SOP development to elevate skill depth and operational consistency. • Increased output of two primary lines by 15% through layout reconfiguration and strategic equipment upgrades.

Finite Element Analysis,Plastics-Extrusion-Plastic and Pipe, Thermoforming-Plastics,Injection Molding-PVC/ABS/PPR

B.E Mechanical Engineering