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Ali Rehman Zaki SUPPLY CHAIN | OPERATIONAL EXCELLENCE | SIX SIGMA GREEN BELT
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Progressive leader with over 13 years of experience in Manufacturing, Operational Excellence and Quality aspects of Supply Chain with globally renown FMCG organizations like Coca-Cola, Unilever, Almarai and Mondelez International. I am certified Six Sigma Green Belt and have successfully completed Lead Auditor course for QMS 9001, ISO 450001 OH&S Management System. I'm skilled in developing effective relationships and commanding a service-oriented approach. I'm passionate about achieving high standards and continually raising the bar. I'm seeking to leverage my experience, deliver in challenging environments, and lead large-scale teams across different geographies.

Work Experience


Almarai Company KSA
Corporate Quality Compliance & Improvement Manager (Sep 2016 to Mar 2018) 1 Year & 6 Months
• Developed and implemented systems and procedures relevant to Manufacturing, Operations, Warehousing, Retail & Medical Sales, Marketing, Procurement, Exports and R&D in align with Almarai Quality Systems, ISO 9001:2015, FSSC 22000, HACCP, CODEX and AIBI. • Managed more than fifty suppliers spanning across ME and EU for ingredients and packaging material, led supplier approval and qualification of ingredients and packaging materials as per Almarai Supplier Quality Management guidelines. • Managed stringent timeline of 3 months for negotiation with suppliers on specification agreement and sign-off of ingredients required for launch of new ready to drink infant formula products along with arrangement of trial samples for material qualification at site. • Act as Risk Management coordinator for Infant Nutrition Division and responsible for review and update of divisional risk register with all the stakeholders. • Work with Central Procurement Department (CPD) in development of new suppliers for ingredient and packaging materials and developed Supplier Risk Matrix to ascertain Supplier rating and audit frequency.
Unilever Pakistan Ltd.
Site Quality Manager (Mar 2014 to Sep 2016) 2 Years & 6 Months
• Implemented Unilever specifications, standards and Quality Management System (QMS) for quality assurance and controls in alignment with applicable regulatory requirements for beverages category, includes Unilever own site and one 3rd Party Manufacturing site. • Led category transformation from FSMS to FSSC 22000, and achieved first ever FSSC certification for UL site and co-packer. • Implemented Quality Control Pillar of WCM and drive product quality improvement projects using WCM methodology. Led global “Top 5 for Zero” challenge to achieve Zero foreign matter complaint and Zero product recalls target in 2015. • Worked jointly with UL Engineering team on Project Shift involving CAPEX of 12 Mn € which has the aim to replace obsolete technology of packing machines with core design compliant technology to improve product quality. Successfully delivered installation & commissioning of high speed line with mitigation of quality and food safety risk through Design HACCP and achieved 99% CRQS for critical on-pack defects. • Led Global Project Big Bang from PK which has aim to harmonize and align SAP QM usage across all manufacturing sites of Unilever. • Worked with R&D and Supply Planning under umbrella of Project Moonlander to Introduce PLM which will provide a digital workbench to manage formulations, packaging and processing design data from concept to final specification.
Mondelez International
Quality and Food Safety Executive (Jan 2011 to Mar 2014) 3 Years & 2 Months
• Developed HACCP and sanitation plan for confectionary and powdered beverages plant as per Mondelez Global QPs. • Provided support to R&D in ongoing innovation/renovation projects for both chocolates and powdered beverage category. • Led Perk Quality Improvement project regarding wafer sogginess by studying gluten content in flour using DMAIC approach and reduced absolute consumer complaints to 66%.
Coca-Cola Beverages Pakistan Ltd.
Plant Manager (Apr 2018 to Present) 5 Years & 11 Months
• Leading bottling operation of beverage plant with high-speed lines, 50M unit case capacity and managing 150+ team, overseeing production, maintenance, quality, safety, warehousing and logistics. • Responsible for overall financial planning of $5M OPEX and execution of strategic project OTIF against approved CAPEX. Oversee toll fill operations, financials, and service contracts. • Leading region's sustainability roadmap, coaching future leaders, improving D&I score, and creating bench strength and succession planning for critical roles. • Reduced Manufacturing overhead (MOH) of the plant by 5.5% vs Business Plan for 2022 and approx. 9% to PY 2021 through optimized consumption of consumables, Identifying cheaper alternate sources for spares and services, SLAs. • Led transformation journey of Karachi Plant and won award of Most Improving plant for two consecutive years in SC Champions League across 33 plants in 11 countries. • Improved material yields by 150 bps through focused Operational Excellence projects, resulted in YoY savings of 0.5M USD in the COGS. • Leading construction of Greenfield Bottling Plant with capacity of 120 million unit cases with three state of the art bottling lines in aligned with Coca-Cola Quality Growth Algorithm strategy.

Education


University of Karachi
B.S in Industrial Chemistry (2007 - 2010) 
Four years Bachelors degree in Industrial Chemistry with specialization in Food Technology

Professional Courses and Training


Six Sigma Green Belt
Successfully completed Six Sigma Green Belt in Sep 2022
Lead Auditor for ISO 9001:2015, ISO 45001:2018, FSSC 22000
Completed Certified Lead Auditor courses for ISO and FSSC standards in 2023
IOSH Managing Safely v5
Organized by SGS Pakistan Ltd in May 2023
SL Level-II Coaching Certificate
Successfully completed level-II workshop for coaching by Blanchard in Aug 2022
Advanced Production Management System
Organized by Coca-Cola CCI in 2018
Advance HACCP, Sanitary Design of Equipment and Sanitation Controls
Organized by Mondelez International EMEA Region, Dubai, UAE in 2013

Technical Skills

  • Supply Chain Operations
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  • Quality Management System
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  • Operational Excellence
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  • Warehousing & Logistics
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  • Business Assurance
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  • Health & Safety Management
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  • Data Analysis & Reporting
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  • Operational Finance (OPEX/CAPEX)
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  • Microsoft Office, Power BI
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Personal Skills

Adaptable

Communicative

Organized

Goal Oriented

Innovative

LANGUAGES

Urdu
Native or Bilingual Proficiency
English (UK)
Professional Working Proficiency

PERSONAL

Nationality
Pakistan
Date of Birth
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Marital Status
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Driving License
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Major Achievements

- Won "Most Improving Plant" award for two consecutive years 2022 and 2023 in SC Champions League between 11 countries and 33 plants.
- In aligned with The Coca-Cola Company AWS program, reduced Water Usage Ratio (WUR) to 10% vs LY through focus improvement projects, using DMAIC approach, enabling CCI Pakistan to improve 3% on country level.
- Reduced MOH of plant to 5.5% vs Business Plan for 2022 and approx. 9% to PY 2021 through optimized consumption of consumables, Identifying cheaper alternate sources for spares and services, SLAs.