Cost Management of a Pakistani Factory

Cement Industry of Pakistan

 

Below report provides an analysis of Cost Management in terms of different Human Resource positions and roles in typical Pakistani factory:

 

NamePositionDepartmentLocationReport ToNo. Of Direct ReportsNo. Of Staff Reporting Directly Or Indirectlyaddress1Purpose Of The JobAuthority LimitsResponsibilities
Fuad AzamSite Safety Officer Grade G-8Health Safety & Environment DepartmentWest WharfMs. Zulekha A. SoormaTo Ensure That HSE Guidelines are implementedSafety inspections  30%

HSE audits 20%

Monthly reports 10%

Departmental safety committee meetings 10%

Trainings 20%

Investigation reports, other reports, HSE audits & follow-ups 10%

Haroon Murtaza KhanG-8 Senior ExecutiveFinanceLahore FactoryManager Finance LFOneOnePayables, Cash And Bank Reporting And RecordingChecking and preparation of payable general vouchers and payment vouchers 20%

Preparation of cheques 15%

Preparation and dispatching of income tax challans 10%

Bank reconciliation 10%

Management staff payments 5%

Local reporting like meal & medical statements, advances to suppliers etc. 5%

3Cash forecast, inter office reconciliation and debit notes 5%

Re3conciliation of creditor’s ledger 10%

Accounting and record keeping of accruals and prepayments 5%

Deduction of tax at source reports 5%

Muhammad Iqbal –LF ExecutiveG-9FinanceLahore FactoryManager Finance LFOneTwoTo Control, Manage & Report StocksPurchase, consumption & reconciliation of raw and packing materials 20%

Incurrance, absorption & retention of price variance and its reconciliation 13%

Group,  management & statutory  reporting of stocks 10%

Recording, provision & adjustment of goods in transit 15%

Accounting, consumption & reconciliation of engineering & consumable stores 5%

Reporting and reconciliation of finished goods & WIP 5%

Audit, control & checking of raw, packing, FG, & WIP and reporting there on. 5%

Control of bank guarantees, indemnity bonds & insurance claims 5%

Supervision of payroll, preparation & payment processes 10%

Government returns 2%

Management & head office queries 5%

Syed Asad Kabir  -LFAccounts Executive  G-9Budget & Cost/FinanceLahore  FactoryManager Finance- Mr. Abid AliOneTo Record, Manage & Control CWIP, Fixed Assets And ComputerizationRecording of CWIP 5%

Capitalization of fixed assets 5%

Accounting of fixed assets 15%

Transfer of fixed assets 10%

Depreciation of fixed assets 20%

Computerization of fixed assets 30%

Deletion of fixed assets 5%

Physical checking & tagging of BPM assets 5%

Muhammad Javed AkhtarExecutive / G9Budgeting Planning/ FinanceSykes Building, West Wharf, KarachiDy. ManagerTo Assist And Perform Various Activities Of Budgeting & PlanningPreparation of 5 years budget/ forecast & cost of sales (Singapore, UK) 19%

Phased budget 5%

Estimates + 1 April & estimate September &  other revision (Singapore, UK) 8%

GFACSS (reporting to U.K. of budget /forecast) 5%

Products costing for (NPC & pre-NPC, assist in preparation of products feasibility, price revision (MOH), hardship cases, export products, tender inquiry, special contracts) 20%

Assist in preparation of debtors analysis report 2%

Assist in preparation of cash forecast 2%

Sales & GP analysis ( monthly) standard 10%

Sales price/ volume analysis (monthly) 5%

Assist ECM presentation sheets 5%

Assist products net contribution statement & other analysis 6%

Special working for overseas visitor’s presentation preparation analysis & checking 3%

To carry out other special assignments & other miscellaneous work as and when required 10%

 

Syed Pervez A. RizviSenior Executive / G8Budgeting Planning / FinanceSykes Building, West Wharf, KarachiDeputy ManagerPreparation Of The Budgets & Forecasts

Analysis & Control Of Expenditures Using Toolkit Of Budget

Working For Better Prospects Of Company And Provide Satisfaction To My Seniors.

Preparation phased budget (complete with P&L /B.S.) for local management. (uploading on as/400) 7%

Preparation of April estimate +1 (Singapore/ U.K.) Singapore forms / e forms 9%

Checking / preparation of presentation sheets & analysis 10%

Preparation of phased capital expenditures budget and control/monitor the CAPEX with budget 2%

Special working for overseas visitor’s presentation preparation analysis, checking, booklet 3%

Analysis, checking of 142 cost centre expenditure in major grouping 20%

Preparation of phasing budget (complete with P&L/ Balance sheet) for the year & forecast period, checking of revenue/capital expenses. Discussion with the departments for 142 cost centre. Complete the “B” & “D” series form pack for U.K. 34%

Preparation of phasing budget (complete with P&L /balance sheet) for U.K. on excels & filling of phasing “B” form pack. 5%

3Miscellaneous work: different type of profitability, coordinate with general accounts to solve the queries 10%

Azhar RashidSenior Executive G-8Quality Assurance (Syrup Section)D/43, S.I.T.E.Deputy Manager (Ms. Shahida Jawed)TwoTwoTo Ensure that the Batches released should meet the standard specification and released according to the Customer Demand.3Analysis of fresh batches and their timely release 45%

3Preparation of analytical  documents 10%

3Preparation and maintenance of standards, chemicals & reagents 10%

3Training of junior staff 10%

3Support in the maintenance of laboratory instruments 5%

3Review/ validate analytical methods 5%

3Proper destruction of tested samples 5%

3Updating of substance in formation sheets 5%

3Part time role in the project (building new lab.) 5%

Samina MateenSenior Executive G-8Q. A. (Micro Lab)  TechnicalD/43, S.I.T.E.Deputy ManagerOneTo Give Quality Services To Company3Microbiological testing 55%

3Sops writing 10%

3Validation work 15%

3HSE compliance 10%

3Documentation 10%

Rashid MallickSenior Executive (G-8)Stores / TechnicalF – 268Manager StoresThree (03) +1To Ensure That Materials Are Kept And Issued As Per Company PolicyAs Per Company Policy3Receipt of material 20%

3Controlling issues 30%

3Proper maintenance of record 20%

3Staff training 10%

3Cycle counting 5%

Syed Mubashir HussainSenior Executive (G-8)Production Control / TechnicalWest WharfSenior Manager Production Planning & Inventory ControlTwoTwoTo Ensure On  Time Availability Of Finished GoodsAs Per Limit Of Authority3Preparation & issuance of packaging and production program 10%

3Follow-up of production program 20%

3Sample supply 5%

3Export / institutional orders execution 5%

3Ensure proper documentation as per system 5%

3Making sure the availability of materials 10%

3Close liaison with all related departments 20%

3Preparation & follow-up of preventive maintenance schedule of machines 5%

3Bulk issuance of shop orders 5%

3Reports preparation ( program deviation, outstanding orders, materials shortages) 10%

3Record maintenance (  shop orders initiation/ deletion / maintenance , production for the month & year, b. Nos. & date of mfg. Shop order close etc.) 5%

Muhammad AslamExecutive (G-9)Production Control/ TechnicalF-268Senior Manager Production Planning & Inventory ControlTo Plan, Control & Smoothline The Production Flow In Such A Way That The Marketing Requirement Could Be Meet In TimeAs Per Company Policy3Cost effective production planning of both sale & sample to achieve marketing target. 35%

3Coordinate & control the manufacturing & packing of products 35%

3Managing , organizing & executing the export orders 5%

3Planning for machine maintenance 2%

3Maintain up to date status of different reports to be submitted. 3%

3Generation & maintenance of shop orders & send to concerned department 10%

3Timely executing other activities /task assigned 10%

Tehseen MalikExecutive (G-9)Production Control / TechnicalLahoreDeputy Manager Production  ControlOneOneEnsure Availability Of Finished Goods To Marketing & Sales Dept. As Per Schedule /PolicyAs Per Company Policy3To ensure smooth running of the activities of production control dept. In lahore factory 20%

3Production planning & follow-up 30%

3Material planning 15%

3Preparation of monthly & weekly reports 15%

3To held meeting with production dept. 10%

3To held meeting with procurement dept. 10%

Ilyas KhanExecutive G-9Production Control/ TechnicalF-268Deputy Manager Production ControlTo ensure on time availability of MaterialsAs per Company Policy3Generation of Purchase Requisitions 15%

3Entry to P.R. in MRP which includes addition, alteration, deletion, & proper filing 15%

3Follow up with QA to get the material passed 5%

3All types maintenance of shop order which includes Enquiry, Close operation, work centre changes and other operations 10%

3Several reports required to the department which includes Audit trail, MRP, Outstanding PR, Routing list, Bill of material input data print and others 15%

All  the process of rebate claims from start to finish 15%

3Special works whenever assigned 10%

3To entertain different enquiry from the production and other departments 15%

Nadira KhanSecretary to Director of Production Executive Grade G-9Technical Directorate / TechnicalF-268, SITE, KarachiDirector of ProductionI handle the entire secretarial job of Director of Production Dr. Saif ul Malook3Taking of Dictation and typing 0 drafts, letters, memos, reports etc. collection and compilation of data for preparation of monthly reports. Preparation of slides to be shown in the meetings / conferences. 60% 3Photocopying of documents, filing, operating of Computer, faxes, mail etc 20%

3Handling all incoming and outgoing telephone calls, receive messages, faxes, mail etc of my Boss. 10%

3Maintenance of Boss’s dairy, arrange official meetings / appointments and review / follow-up of all pending work 10%

Nusrat JehanSenior Executive Officer G-8Projects (Operations) / TechnicalF-268 SITEDirector Projects (Operations)Those involved in Projects validation Activities1.      Documentation

·       Preparation of SOPs, VMPs & Performance Qualification Protocols relating to projects leading towards integration of production / QA Facilities.

·       Keeping Records of Validation Protocols/ Results & Change Control Documents.

2.      Validation (Performance Qualification):

·       Evaluation & Performance of Validation in coordination with Production, QA and Engineering.

3.      Data Monitoring ( Performance Qualification)

·       Compilation of Validation Data, Analysis of Results & Highlight areas of improvement in-accordance with Group Quality Policies.

·       Submission of Validation Data for approval of Director Projects (Operations).

4.      Coordination

·       Liaise with Director Projects (Operations) to smooth handover of Projects Task Force Meetings.

·       Secretary Projects Task Force Meetings

·       Member of Projects Steering Committee.

As per limit of authority given by company3Documentation 40%

3Validation(Performance Qualification) 40%

3Data Monitoring 10%

3Co-ordination 10%

Sohail AhmedSenior Executive / G8 (Produiction Floor)Engineering / Technical D/43D/43Dy. Manager MaintenanceNineNineMaintenance of production plants, equipment, and other production related services to meet agreed production levels and fulfilling GMP, HSE and regulatory requirements.1,500/= for store withdrawals3Ensure that all above mentioned systems are kept in perfect running condition to meet production, quality and regulatory requirements. 35%

3Control the activities of all staff and outside contractors in accordance with the company rules and policies 15%

3Implement safety requirements and ensure improvements in GMP, Health, Safety and environmental aspects as per Glaxo Wellcome guidelines 10%

3Carry out preventive & routine maintenance of plant and equipment to ensure trouble free operation. 10%

3Ensure that running faults are removed in minimum possible time and do not leave the work place without permission, until the problem is rectified. 5%

3Personally supervise maintenance work on major machines & ensure that standard procedures followed. 5%

3Be available on shop floor visit each plant and equipment daily and ensure that adequate attention is being paid to the operation and maintenance. 5%

3Ensure proper record keeping of maintenance work and provide progress reports / feedback to Dy. Manager maintenance. 5%

3Make efforts to improve efficiency of plant and equipment, develop standby systems for smooth operation and ensure on time availability of spares 5%

Abid SubhanSenior Executive / G8 (Utilities D43)Engineering / TechnicalD/43Manager MaintenanceEightEightOperations and maintenance of steam water, D.I.  Water , and fire fighting systems, including operations of compressed air, central vacuum systems, maintenance of weighing balances and passenger / cargo lifts to meet agreed service levels within budget limits and fulfilling group ‘s GMP and HSE standards. Also, maintain inventory of engineering spares as per agreed stock policy.1,500/= for store withdrawals3Ensure that all above mentioned systems are kept in perfect running condition to meet production, qulaity and regulatory requirements. 35%

3Ensure that purchase requisitions for stock item are raised on time for maintaining agreed stock levels in the engineering store. Also review the consumption of stocks and recommend adjustments in the stock policy. 15%

3Control the activities of all staff and outside contractors in accordance with the company rules and policies. 10%

3Implement safety requirements and ensure improvements in GMP,  Health, Safety and environmental aspects as per Glaxo Wellcome guide lines 10%

3Train and develop staff to increase their technical competence for sufficiently carrying out preventive and routine maintenance work. 5%

3Be available on shop floor, visit each plant and equipment daily and ensure that adequate attention is being paid to operation and maintenance. 5%

3Arrange to carry out preventive/ routine maintenance of palnt and equipment to ensure trouble free operation 5%

3Ensure proper record keeping of maintenance work and provide progress reports / feedback to Manager maintenance. 5%

3Make efforts to improve efficiency of plant and equipment, develop standby systems for smooth operation and ensure on time availability of spares 5%

3Ensure that running faults are promptly rectified and any break down is handle in such a way that there is minimum possible affect on the production outputs. 5%

Zafar AhmedExecutive / G9 (HVAC)Engineering  / TechnicalD/43Manager MaintenanceTwoTwoOperation and maintenance of entire air handling system, including chillers, air handling units, packe / split unit, complete with ducting, filters, dampers etc. window air conditioners, water coolers and humidity control system to meet agreed service levels within budget limits and fulfilling GMP/HSE and regulatory requirements.1,500/= for store withdrawals3Ensure that all above mentioned systems are kept in perfect running condition to meet production, qulaity and regulatory requirements. 35%

3Control the activities of all staff and outside contractors in accordance with the company rules and policies 15%

3Implement safety requirements and ensure improvements in GMP, Health, Safety and environmental aspects as per Glaxo Wellcome guidelines 10%

3Carry out preventive & routine maintenance of plant and equipment to ensure trouble free operation. 10%

3Ensure that running faults are removed in minimum possible time and do not leave the work place without permission, until the problem is rectified. 5%

3Personally supervise maintenance work on major machines & ensure that standard procedures followed. 5%

3Be available on shop floor visit each plant and equipment daily and ensure that adequate attention is being paid to the operation and maintenance. 5%

3Ensure proper record keeping of maintenance work and provide progress reports / feedback to Manager maintenance. 5%

3Make efforts to improve efficiency of plant and equipment, develop standby systems for smooth operation and ensure on time availability of spares 5%

S. A. H. NasirExecutive / G9 (Electrical)Engineering / TechnicalD/ 43Manager MaintenanceFourFourOperation and maintenance of electrical installations comprising HT/LT switch, gears, transformers, sub-distribution network , standby generators emergency, electrical supply, lifters and other electrical appliances and systems to meet agreed service levels within budget limits and fulfilling GMP/HSE and regulatory requirements.1,500/= for store withdrawals3Ensure that all above mentioned systems are kept in perfect running condition to meet production, qulaity and regulatory requirements. 35%

3Look after routine and preventive maintenance of all electrical installations, HT/LT switch, gears, transformers, sub-distribution network, standby generators emergency lighting and other electrical appliances and systems. 10%

3Control the activities of all staff and outside contractors in accordance with the company rules and policies 10%

3Implement safety requirements and ensure improvements in GMP, Health, Safety and environmental aspects as per Glaxo Wellcome guidelines 10%

3Carry out preventive & routine maintenance of plant and equipment to ensure trouble free operation. 10%

3Ensure that running faults are removed in minimum possible time and do not leave the work place without permission, until the problem is rectified. 5%

3Personally supervise maintenance work on major machines & ensure that standard procedures followed. 5%

3Be available on shop floor visit each plant and equipment daily and ensure that adequate attention is being paid to the operation and maintenance. 5%

3Ensure proper record keeping of maintenance work and provide progress reports / feedback to Manager maintenance. 5%

3Make efforts to improve efficiency of plant and equipment, develop standby systems for smooth operation and ensure on time availability of spares 5%

3Removing running faults in machines in minimum possible time and ensure availability of production plants for standard output 5%

Afzal ShadSenior Executive / G8 (Production Floor)Engineering / TechnicalF/268Dy. Manager MaintenanceNineNineMaintenance of production plants, equipment, and other production related services to meet agreed production levels and fulfilling GMP, HSE and regulatory requirements.1,500/= for store withdrawals3Ensure that all above mentioned systems are kept in perfect running condition to meet production, quality and regulatory requirements. 35%

3Control the activities of all staff and outside contractors in accordance with the company rules and policies 15%

3Implement safety requirements and ensure improvements in GMP, Health, Safety and environmental aspects as per Glaxo Wellcome guidelines 10%

3Carry out preventive & routine maintenance of plant and equipment to ensure trouble free operation. 10%

3Ensure that running faults are removed in minimum possible time and do not leave the work place without permission, until the problem is rectified. 5%

3Personally supervise maintenance work on major machines & ensure that standard procedures followed. 5%

3Be available on shop floor visit each plant and equipment daily and ensure that adequate attention is being paid to the operation and maintenance. 5%

3Ensure proper record keeping of maintenance work and provide progress reports / feedback to Dy. Manager maintenance. 5%

3Make efforts to improve efficiency of plant and equipment, develop standby systems for smooth operation and ensure on time availability of spares 5%

Naiman Yar KhanElectrical Engineer ( Executive Grade)Engineering / TechnicalWest WharfFourKeep all production and service equipment in operation, make regular improvements to enhance efficiency. Carryout periodical maintenance of all electrical / electronic devices.Rs. 3,000 (Engineering Stores limit for issuance of spare parts)3Ensures that all production and service equipment etc. are kept in the manner and levels specified by the company. 10%

3Ensures smooth operation of production machines, specific emphasis should be made on maintenance of H.T., L.T. switch gears, transformers, generators electrical installations. 25%

3Update all electrical equipment list on regular basis & ensures all technical date is provided in the list. 5%

3Prepare requisitions of spare parts as and when required. 5%

3Ensures improvement in HSE issues as per GRM’s recommendations. 5%

3Provide input to prepare preventive maintenance plan for area of responsibility and ensure is effective implementation. 5%

3Guide technical staff to carry out routine maintenance work efficiently. 10%

3Coordinate with other units to ensure build up of team work 5%

3Maintain proper record of electrical installations, maintain comprehensive list of electrical equipment including their installed electrical load. 10%

3Carry out validation of production machines service equipment (motor, gauges etc.) & maintain proper record. 10%

3Carry out leakage and insulation testing on yearly basis. 2%

3Prepare West Wharf Sites for annual electrical inspection carried out by Licensing authorities. 3%

3Maintain Fire System. Carry out its regular maintenance and maintain record. 2%

3Carried out special projects as & when assigned to. 5%

3To highlight areas of training for sub-ordinate staff to encourage them to acquire new skills and polish the existing areas. 5%

Mr. Noel U’ ChongUtility Engineer (Executive Grade)Engineering / TechnicalWest WharfNine

 

Keep all production and service equipment in operation, make regular improvements to enhance efficiency. Carryout periodical maintenance of all electrical / electronic devices.Rs. 9,000 ( Engineering Stores limit for issuance of spare parts)3Ensures that all air conditioning and utilities equipment etc. kept in the manner and levels specified by the company. 10%

3Ensures smooth operation of A/C machines & generators/boilers & compressors and carry out regular maintenance of these machines. 25%

3Prepare requisitions of spare parts as and when required. 5%

3Ensures improvement in HSE issues as per GRM’s recommendations. 5%

3Provide input to prepare preventive maintenance plan for area of responsibility and ensure is effective implementation. 5%

3Guide technical staff to carry out routine maintenance work efficiently. 10%

3Coordinate with other units to ensure build up of team work 5%

3Maintain proper record of machine history, maintain comprehensive list of equipment and update the list as and when necessary 3%

3Carry out validation of A/C machines, generators, compressors & boilers & maintain proper record. 10%

3Prepare boilers for annual inspection from licensing authorities. 2%

3Validate pressure gauges and all pressurized vessels. 2%

3Update plant & machinery list on regular basis & ensure all technical technical data is provided in the list. 3%

3Carried out special projects as & when assigned to. 5%

3To highlight areas of training for sub-ordinate staff to encourage them to acquire new skills and polish the existing areas. 10%

Javed AslamSenior Executive (G-8)Production-Packaging / TechnicalF-268, SITE, KarachiDeputy Senior  Manager Production/ PackagingThree108To pack the products, qualitatively and quantitatively according to market demands.As per limit of authority given by company3To discuss & co-ordinate production plan with production control and liquid production.5%

3To supervise all operations involved in packing of products on specified belts of packaging dept. 50%

3To supervise all operations involved in bottles blowing.15%

3Training of packing personnel for related matters. 15%

3To co-ordinate with Q.A. to determine the status of release of packed products. 5%

3To ensure proper documentation, liquid products, spillage storage and its delivery to Lahore for inceration. 10%

 

 

Abdul MajeedSenior Executive (G-8)Production- Packaging / TechnicalF-268, SITE, KarachiDeputy Senior Manager Production/ PackagingFour150To pack products, according to GMP. To implement production plan and to pack the products within time frame.As per limit given by company3To implement production plan within packing department. 25%

3To supervise all operation involved in carrying- out different areas of packaging dept. F-268.

3To supervise the issue of packaging material from store. 10%

3To print the packaging of different products for smooth running in belt.15%

3To co-ordinate with Q.A. to determine the status of release of packed products. 10%

3To prepare Different types of report 20%

3Miscellaneous work 5%

Khalid Mahmood MirzaSenior Executive (G 8)Production – D/43 /TechnicalBlister / Strip / Powder Filling AreasDeputy Senior Manager ProductionFive31To contribute to the growth and profitability of Glaxo Wellcome through processing of Non-Sterile range in general and tablet in accordance with company’s policies.Personnel Gate Passes3To supervise all operations involved in carrying out various function of Blister / Strip / Powder areas. 50%

3To maintain various records related with areas. 5%

3To make all necessary efforts through personal interest and experience to boost the production activities to maximum. 10%

3To look after and supervise the activities of the other section of the department as and when required like Animal Health 10%

3Good House Keeping / Miscellaneous activities 5%

3To contribute for safe system of work as per approved company policy related to HSE. 5%

3To carry out any other work assigned by the Management. 10%

3To provide information required to implement BPCS Version-6. 5%

 

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