Usman Bhatti

• Sets and monitors SPS data to ensure delivery of consistent quality. Utilize basic quality tools to analyze for trends and issues.
• Identify, develop and implement process controls to meet customer/specification requirements.
• Develops/authors verification, qualification and validation protocols ( i.e validation plans, IQ/OQ/PQ protocols, validation summary reports.)
• assist and coordinates equipment, cleaning and process validations.
• Participate i and support the maintenance of the quality management system and maintain quality department business metrics.
• Lead and support investigations of the quality issues (CAPA's, Non-Conformances, Audit Observations, OOS investigations etc.) ensuring effective, corrective and/or preventive action occur.
• Participate in cross-functional teams on process control, optimization and continuous improvements projects
• Ensure all quality specifications are met for any product and also the components in line for any vendor and facility
• Approving the format of COA for new materials and products in the system

• Maintained technical datasheets, MSDS and catalog information.
• Performed drug testing according to the standard procedures of USPA in case of acetaminophene,ascorbic acid,diphenylhydramine HCL, niacine and more
• Kept lab according to set standards by calibrating equipment and performing preventive maintenance.
• Quality testing through HPLC, FTIR, Atomic absorption, Spectrophotometer, Viscometers, and different lab instruments following appropriate analytical procedures according to USPA.
• Studied deviations from established specifications or parameters in results.
• Followed safety procedures when handling materials and discarding waste.
• Following cGMP in lab work

• Optimize and coordinate planning for scheduled start-ups and shutdowns, supervisors and operator trainings.
• Dyeing process simulations and operations by using Orgatex 7.0 / Chemcad applications for reaction completion of dyes and fabric and optimization of the process for good reproducibility
• Supervision of wet analysis of plant production (Fabric), chemicals and utilities for dyeing include pH, TDS, conductivity, concentration by refractometer, spectrophotometer, acid/base titration (manual and autotitrator), viscosity by viscometer, anionic/nonionic titration and ICP, IC, FTIR, spectrometer use.
• Complete programming, process analysis and optimization of dyeing reactors by Oragatex(DCS) to identify time delays, process faults, non-conformities and direct team members for reduction of such NC's in future (Root Cause Analysis)
• Implementation of preventive maintenance plans of dyeing reactors considering production priorities
• Conducted sampling programs to analyze quality standards of raw materials, chemical intermediates and products.
• Documented experiment findings in technical lab and production reports and data graphs.
• Completed analysis of solids and liquids materials to assess nature and reactivity before having any quality issues in product (dyed fabric)

• Sapphire Fibers Limited is producing 7200 TPA dyed finished fabric
• Roles and responsibilities:
• Optimization and modification of process procedures according to the machine functions and process requirements to reduce the batch timings and utilities consumption
• Responsible to meet weekly production target adherence of each and every customer
• Implementation of preventive maintenance plans of dyeing machines considering production priorities
• Responsible to maintain minimum reprocess rate and planning reprocess things besides fresh production
• Manages open & tubular fabric load according to finishing WIP & customer priorities after discussing with PPC
• Cross checking of production report and highlight the wrong steps taken in any batch dyeing procedure
• Checking daily production formats, time delay, chemical dyes and production records to date
• Cost reduction of per batch by optimizing the use of utilities and pretreatment chemicals customer wise.

• Sapphire Fibers Limited was producing 2400 TPA dyed finished yarn and surgical cotton
• Controlling the process by ORGATEX (DCS) software and get things done and plan using oracle applications
• Complete programming and process analysis by ORGATEX (DCS) to identify time delays, process faults, non-conformities and direct team members for reduction of such NC’s in future
• Interact frequently to respond the persistent follow-ups of all orders which are under process, notifies the reason behind the delays in delivery of order and suggest suitable timelines for export and commercial parties
• Responsible for adjusting recipes of non-blind batches, combination for new developments and selection of best shade recipes from research and development lab
• Good command on all type of dyeing profiles mainly isothermal, VAT, cooling down, turquise, acrylic and procion mainly
• Responsible for the predevelopments in case of dyestuffs or yarn source change to run department smoothly
• Maintaining major planning sheets to make time and action plans considering capacities for on time PO closing
• Record keeping of yarn variation and pre-production developments for future orders
• Responsible for preproduction & execute production plan to achieve production targets
• Checking the plant dyeing machines for calibration and operational faults
• Managing and educating supervisors and plant operators to standardize the process according to SOP and visit floors randomly to observe whether the guidelines of processing are being followed at machines or not
• Understanding of level and temperature control loops (cascade loops) , their inputs and outputs variables finally to PID controllers to maintain a steady reaction state of dyeing process.

Zenith Chemical Industries is producing 720MTPA Paracetomol, 100 MTPA Ciprofloxacin HCl and 120 MTPA Ibuprofen as per BP/USP standards

• Handling all the process involved in Acetylation of Para Aminophenol, refinement and pulverization
• Performed necessary Energy and Mass Balance of the newly erected Plant of PAP to APAP
• Prepare PFDs, P&IDs and managed all the fabrication and installation of Pipe and Process Lines
• Made necessary changes to meet our Production targets
• Performing different process like Distillation, Reflux, Purification and Acetylation
• Part of the team performed cost estimation of LIN (liquid Nitrogen) to replace Chiller water
• Preparing monthly reports and other documents i.e
• JD’s, BMR and MSDS
• Preparing SOP’s, washing and decontamination records and documents necessary for GMP training for external audit and validation by GSK

Plant Utilities:

• Complete overview of utilities
• 20 TPH coal or rice husk fired step grate water tube steam boiler maintaining 15 bar working pressure made by WUXI ZOZAN china
• 100 m3/h of reverse osmosis water plant for plant dyeing operation and boiler feed water
• Capacity of 37 KW Screw compressors at 11 bar and 2 air dryers by KESSER

• Synthesis and characterization of Sodium A-zeolite
• CCR Platforming of hydro-treated naphtha with capacity of 20,000 bbl/day

• Up gradation of laboratory double pipe heat exchanger and cooling tower
• Design of level control loop of fired tube Laboratory boiler of i ton capacity