junaid Ali Malik

General Manager - Technical & Engineering

Phone: 332 9062198

Sector: Engineering, Engineering, Procurement & Construction, Fast Moving Consumer Goods (FMCG), Utilities

Salary: 1150000PKRs / Monthly

(Age: 46 years)

House # 1069, Street # 54, Block C, MPCHS, Sector B-17 Islamabad. , 44000 Member Since, October 2, 2025

About junaid Ali Malik

Gender Male
Job Fuction Engineering
Academic Level Master’s Degree
Degree Title M.S in Industrial Engineering
Start Date 06-04-2009
End Date 24-06-2011
Viewed 79

About me

A strategic and accomplished leader with over 24 years of progressive experience in Plant Engineering, Maintenance, and Operations Management across the FMCG, beverage, and manufacturing industries. Renowned for driving organizational transformation, operational excellence, and sustainable performance improvements, I have successfully led multi-site, multi-shift operations—ensuring alignment between technical execution and business strategy.

Throughout my career with leading organizations such as OCOCO DMCC, Haleeb Foods Ltd., Pepsi Cola International, and ZRK Group of Industries, I have championed initiatives that enhanced profitability, production reliability, and quality compliance, while fostering a culture of efficiency, innovation, and continuous improvement.

A strong advocate of Lean Six Sigma methodologies and data-driven decision-making, I specialize in optimizing manufacturing systems, improving asset reliability, reducing operational costs, and building high-performing cross-functional teams capable of meeting ambitious KPIs and long-term corporate goals. My leadership philosophy emphasizes strategic agility, operational resilience, and people empowerment as the cornerstones of sustainable success.

Education

2008 - 2009
City University Peshawar.
Masters of Business Adminstration (M.B.A).

I have done my executive MBA from City University peshawar.
1999 - 2003
University of Engineering & Technology, Peshawar.
B.Sc Mechanical Engineering

I have done my bachlors of Engineering in Mechanical Trade with 3.76 cGPA and in honors.

Experience

2016 - Present
ZRK Group of Industires.
General Manager - Technical

Comprehensive Maintenance Management: Managed all maintenance activities across the plant, ensuring
smooth operations for a wide range of critical utilities, including boilers, ammonia chillers, compressed air
systems, and wastewater treatment plants (WWTP). Developed and executed preventive maintenance
plans to avoid breakdowns and prolong the life of equipment.
 Utility Systems Oversight: Provided expert oversight and optimization for plant utilities, including boilers,
ammonia refrigeration systems, air compressors, and WWTP. Ensured efficient operation of all systems
to meet production demands, reduce energy consumption, and maintain safety and compliance.
 Preventive Maintenance Strategy: Implemented a strict preventive maintenance schedule for all plant
machinery and utilities based on OEM recommendations and machine performance data. Proactively adjusted
maintenance routines to avoid breakdowns and extend the lifespan of critical plant equipment, ensuring
maximum operational reliability.
 Equipment Lifecycle Management: Managed the lifecycle of critical machinery using SAP for maintenance
documentation, inventory tracking, and spare parts management. Ensured the timely availability of spares for key
systems, minimizing downtime during unplanned maintenance events.
 Boiler & HVAC System Optimization: Led maintenance and performance optimization of industrial boilers
and HVAC systems, ensuring consistent steam supply for plant operations and efficient cooling for production
areas. Improved energy efficiency through regular system audits and the application of best practices in utility
management.
 Compressed Air Systems Management: Spearheaded the maintenance and optimization of compressed air
compressors, ensuring continuous availability of compressed air for production equipment. Implemented
energy-saving initiatives to reduce air leakage and optimize system performance.
 Ammonia Chiller Operations: Ensured the safe and efficient operation of ammonia chillers for cooling
processes, adhering to stringent safety protocols. Developed emergency response procedures and preventive
maintenance strategies to ensure reliable system performance and mitigate risks.
 WWTP & Environmental Compliance: Directed the operations and maintenance of the wastewater
treatment plant (WWTP), ensuring compliance with environmental regulations and reducing water usage.
Implemented upgrades to improve the treatment process, increasing plant sustainability and reducing operational
costs.
 Inventory and Critical Parts Management: Controlled inventory levels of critical spare parts for utilities and
plant equipment, ensuring quick access during emergencies. Managed the logistical challenges of maintaining a
large, diverse site (spanning over 200 acres) and minimized downtime by ensuring tools and parts were readily
available.
 In-House Modifications & Design Improvements: Led in-house modification and design enhancement
projects, including utility systems, with OEM approval. Coordinated improvements to optimize machine and utility
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performance, ensuring seamless production with the help of a skilled team of engineers, fabricators, welders, and
fitters.
 Installation & Commissioning of World-Class Machinery: Oversaw the installation and commissioning of
imported, state-of-the-art equipment from industry leaders like DIffenbacher, Andritz, Vynke,
Stenimman, Kontra, and Yelin, which integrated fully with PLC/SCADA systems for precision control across
the plant.
 Project Management & BOQ Planning: Managed and executed projects, including utility expansions and
upgrades, with budgets ranging from 10 million to 100 million PKR. Created and monitored Bill of Quantities
(BOQs), ensuring timely project completion and alignment with production goals.
 Direct Reporting & Downtime Control: Reported directly to the Chairman, effectively communicating plant
performance and minimizing both planned and unplanned downtime. Collaborated with management to align
maintenance schedules with production needs, extending equipment life while maintaining operational efficiency.
 Comprehensive Utility and Machine Management: Oversaw utility infrastructure, including boilers,
refiners, cyclones, dryers, chippers, moving floors, forming units, and a 29-meter continuous press
machine. Developed a comprehensive preventive maintenance schedule to ensure the timely lubrication,
greasing, and cleaning of all critical machinery, preventing single-line failures.
 Large-Scale Team Leadership: Led a team of 318 permanent staff and managed 640 daily wagers,
ensuring that all team members were highly trained in plant utilities and machine operation. Promoted a culture
of continuous improvement and operational excellence through rigorous monitoring and ongoing skill
development.
Additional Role: Given Additional tasks of overlooking New Project of Particle Board Line with a production capacity of
3000 M3/day and Glue Raisin Plant with a capacity of 200 Tons of Melamine Glue Production / 24 Hrs.
Key Responsibilities & Achievements:
 Project Lead – Particle Board & Melamine Glue Plant: Spearheading the development of a Particle Board
plant with a production capacity of 3000m³/24 hours and a Melamine glue plant with a 200-ton
capacity. Overseeing the complete project lifecycle from planning to execution, ensuring all phases are
completed on time and within budget.
 Comprehensive Project Planning: Led the end-to-end project planning process, including vendor analysis,
creation of comparative statements for different vendor quotes, and selection based on technical and financial
evaluations. Ensured the highest quality standards in vendor work through rigorous quality checks.
 Contractor Finalization: Managed the finalization of local contractors for civil, mechanical, and electrical
work. Ensured contractors were chosen based on expertise, project requirements, and cost-effectiveness to
guarantee the smooth execution of construction and installation.
 Civil & Structural Integrity Testing: Directed proper civil applications and load testing to ensure structural
integrity of the plant. Defined precise timelines for civil, mechanical, and electrical phases of the project, ensuring
that each phase meets safety, quality, and performance standards.
 Timeline Definition & Monitoring: Established clear and achievable timelines for different project
phases, ensuring alignment with operational goals. Provided daily, weekly, and monthly progress reports to
management, tracking project milestones and addressing any potential delays to ensure timely completion.
 Vendor & Contractor Quality Management: Monitored vendor and contractor performance, ensuring
adherence to design specifications, quality standards, and project deadlines. Conducted periodic audits and
reviews to ensure consistency and quality across all stages of the project.
 Progress Reporting & Timeline Adherence: Ensured the project stayed on track by preparing and presenting
comprehensive progress reports on a daily, weekly, and monthly basis. Coordinated closely with all teams to
ensure that project timelines were met and that any challenges were swiftly addressed.
__________________________________________________________________________
2016 - 2016
Haleeb Foods (Pvt.) Ltd.
Plant Head

Maintenance & Process Machinery Management with Responsibilities:
 Ensured strict compliance with preventive maintenance schedules for all process machinery.
 Managed availability of required spare parts, maintaining a clear schedule for preventive maintenance to
minimize downtime.
 Focused on controlling per liter production cost within the defined range by adhering to maintenance
protocols.
2. Power Generation & Load Management
 Supervised operations of Generators at both plants, ensuring adherence to SOPs for power management.
 Managed 6 x 1 MW diesel generators and 1 x 3.2 MW gas generator, along with 4 x 630 KW Cummins
diesel generators for backup load.
 Monitored sync panels and power panels for real-time load management, ensuring critical loads are
supported at all times.
3. Steam Generation & Boiler Management
 Oversaw the operation and maintenance of 4 High-Speed Furnace Oil-fired boilers, ensuring safety
protocols are followed.
 Monitored steam pressure 24/7 to support critical dairy plant operations.
 Managed a total boiler capacity of 60 tons across two plants.
4. Air Compressors & Refrigeration Systems
 Handled the operations and maintenance of air compressors with a total flow of 70 cubic meters/min,
including preventive maintenance.
 Managed refrigerant dryers paired with air screw compressors to ensure efficient operation.
 Maintained the plant’s chillers (Carrier, York, Trane), with a combined capacity of 1500 RT and introduced a
1800 RT Ammonia chiller to handle production loads of 1.2 million liters/day.
5. Wastewater Treatment Plant (WWTP)
 Managed the wastewater treatment plant with a 75 cubic meter capacity, utilizing de-aeration and
effluent separation processes.
 Ensured the treatment plant effectively separated fat from water and maintained compliance with
environmental regulations for water disposal.
6. Advanced Maintenance Techniques Implementation
 Introduced Time-Based Maintenance (TBM) and Reliability-Centered Maintenance (RCM) concepts on
the shop floor.
 Trained staff on the benefits of these maintenance methods, achieving 97% efficiency compared to traditional
approaches.
7. Tetra Pak Filling Operations
 Oversaw 33 Tetra Pak filling machines at the plant, including 7 A3-Speed machines, 19 TBA-19
machines, 3 TFA A1 Fino machines, 1 TBA-8 machine, and others.
 Managed the smooth operation of high-speed Edge and TCA 65 machines.
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8. Bio-Fuel Boilers for Steam Generation
 Installed and managed two Bio-Fuel Boilers (20 Ton/Hr each) as a cost-effective alternative for steam
generation.
 Ensured these boilers shared the steam load with HFO-fired boilers, improving efficiency.
9. Dairy Product Manufacturing Sections
 Led the revamping and operation of various dairy sections including:
o Butter making, Ghee, Cheese, and Yogurt sections.
 Conducted complete maintenance to bring these units back into efficient operation.
10. Powder Production Plants
 Oversaw the operations and maintenance of Medium Heat and Low Heat Powder Manufacturing Plants at
both locations.
11. Team Leadership & Workforce Management
 Led a team of 84 permanent employees and 38 temporary staff across both plants.
 Ensured smooth operations by coordinating the workforce to handle maintenance and production efficiently.
2015 - 2015
Foragri OCOCO (Cacao Beans Transformation Plant Site).
Director Technical

Technical Leadership & Plant Operations
 Serving as the Technical Head of the plant, overseeing all technical and operational aspects of the facility.
 Ensuring smooth plant operations through comprehensive management of machinery, processes, and staff,
while addressing any technical issues as they arise.
2. General Management & Employee Supervision
 Managing employees across various departments, ensuring day-to-day operations are carried out effectively.
 Overseeing team performance, ensuring targets and KPIs are achieved in alignment with management
objectives.
3. Compliance with Hygiene & Safety Protocols
 Ensuring strict adherence to hygiene protocols as per HACCP and SOPs, maintaining a clean and safe working
environment on the shop floor.
 Implementing all HACCP reforms and BRC protocols, ensuring compliance across production and
maintenance processes.
Production Capacity Enhancement
 Leading initiatives to increase production capacity by planning the installation of new machinery such as
winnowing and tempering lines.
 Identifying opportunities for process improvements and equipment upgrades to optimize production efficiency.
5. Production Optimization
 Ensuring production is optimized to its maximum potential by following production SOPs and continuously
monitoring processes.
 Collaborating with production teams to improve workflow, minimize downtime, and enhance output.
6. Energy Utilization & Power Management
 Planning energy usage based on production load, ensuring efficient energy consumption while maintaining
production targets.
 Managing electric load from both external (CIE) and internal (own power generation) sources, ensuring
consistent and reliable power supply.
7. Preventive Maintenance & Compliance
 Developing and implementing a comprehensive preventive maintenance plan in line with BRC protocols,
ensuring minimal downtime and efficient equipment operation.
 Keeping detailed records of all maintenance activities, including preventive, scheduled, and breakdown
maintenance.
8. Technical Store & Inventory Management
 Managing the technical store by maintaining up-to-date records of critical spare parts and ensuring that all
necessary components are available.
 Monitoring inventory levels, ordering essential items, and maintaining a comprehensive check on records
to ensure efficient plant operation.
9. Reporting & KPI Achievement
 Reporting on key performance indicators (KPIs) and ensuring that the plant meets management objectives
related to production efficiency, maintenance, and safety.
 Implementing strategies to ensure continuous improvement in line with management’s goals and industry standards.
2014 - 2015
Haleeb Foods (Pvt.) Ltd.
HOD Engineering, Maintenance & Utility Department

Engineering Leadership & Factory Operations
 Leading Engineering Operations: Serving as the Engineering Head, overseeing all process and utility
functions within the factory.
 New Equipment Management: Ensuring that all installed machinery and equipment are new, up-to-date, and
running efficiently to produce milk and dairy products around the clock.
2. Process Management
 Homogenization & Pasteurization: Managing the initial homogenization process, also known as
pasteurization, which is crucial for the quality of milk and dairy products post-reception.
 UHT Sterilization: Overseeing the UHT (Ultra-High Temperature) sterilization process, which enhances the
self-life of products like milk, tea whiteners, and juices. Ensuring that UHT equipment operates within the
required specifications for optimal product quality.
3. Tetra Pak Operations
 Tetra Pak Section Management: Managing 26 Tetra Pak machines used for filling various SKUs from
125ml to 1000ml, utilizing some of the latest packaging formats in the industry.
4. Production Units
 Ghee, Butter, and Powder Production: Overseeing the production processes of edible ghee and butter, as
well as managing the state-of-the-art powder manufacturing plant.
5. Project Management
 Haleeb Foods RYK Unit: Led the complete re-vamping of the Haleeb Foods RYK unit, successfully completing
the project in record time of 6 months. Managed all aspects from planning to execution to bring the unit back
online efficiently.
6. Maintenance Strategies
 Implementation of TBM & RCM: Introduced and implemented Time-Based Maintenance (TBM) and
Reliability-Centered Maintenance (RCM) on the shop floor. Educated staff on these concepts, achieving
97% efficiency compared to traditional maintenance methods.
7. Team Development
 Engineer Development: Focused on developing a team of new engineers to tackle upcoming challenges and
support new projects. Fostered a progressive team environment to drive future investments and achieve
significant savings through effective project implementation.
8. Future Projects
 Upcoming Initiatives: Managing several upcoming projects, including:
o Coal Fired Boilers
o Reverse Osmosis (R.O.) Plant
o Water and Energy Conservation Projects
 Ensuring that these projects are strategically planned to provide substantial return on investment and
contribute to overall efficiency and sustainability.
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9. Installation & Commissioning
 Machine Installation & Commissioning: Oversaw the installation, erection, and commissioning of new
machines arriving at the premises. Conducted Site Acceptance Testing (SAT) to ensure that installations meet
all required specifications and standards before proceeding.
2007 - 2014
Northern Botteling Company (Pepsi Cola Bottlers).
Technical Services Manager

Mechanical Installation & Maintenance: Oversee all mechanical installations
and general maintenance across the complete bottling plant.
 Engineering Utilities Management: Manage and maintain all engineering utilities including:
o Compressors
o Submersible pumps
o Electrical panels and wire distribution
o Boilers and cooling towers
o Ammonia compressors
o Reverse Osmosis Plant
o Carbon Dioxide tanks
o Water filtration plant
o Cooling Towers.
o Steam & Air headers.
o Power House with Gas & Furnace powered Generators.
o MCC, MVB & LT Panel Rooms.
 In-House Workshop Operations: Supervise a fully-equipped workshop for:
o Fabrication of small machine parts
o Complex parts fabrication within the factory premises
 Heavy Machinery Maintenance: Manage the repair and maintenance of heavy machinery, including:
o 3-ton forklifts (Toyota, Hyundai, Kumatsu, etc.)
 Civil & Extension Work: Oversee all plant repair work, including:
o Civil work for new sections
o New extension projects
o Drawing approvals and implementation within timeframes
 Cost Reduction & Improvement: Implement time-motion studies and engage staff in KAIZEN
methodology for continuous improvement to minimize product costs.
 Technical Purchases: Handle all technical purchases both locally and internationally.
 Electrical Design & Installation: Design and install:
o Electrical panels and accessories
o Complete wiring for new sections under ASME codes
 SAP Implementation: Introduce SAP for:
o Breakdown & preventive maintenance
o Monitoring circular reports for financial impacts
 Annual Maintenance Planning: Supervise the annual maintenance plan and provide detailed reports
to senior management.
 Machine Efficiency: Optimize the use of existing machines to achieve:
o 80% machine efficiency for meeting production targets
 Energy Efficiency & Financial Savings: Achieve 32% energy efficiency improvements, contributing
to substantial financial savings.
2005 - 2007
Shamim & Company Multan (Pepsi Cola Bottlers)
Maintenance & Project Manager

Responsible for the maintenance work being followed up including the entire preventive and plant maintenance.
Looking after the engineering utilities including the Boilers, Air compressors, Ammonia compressors, Water
treatment plant, R.O.plant etc.
To give a complete yearly, monthly and daily inspection plan to workers and carry out extensive working accordingly
in the company premises.
Working and installation of 10 molds KRONES blow molding machine.
Installation of centrifugal pumps with 70 H.p to carry water to the 250 tons cooling towers and heat exchangers
installed with them.
Installation and commissioning of 40 Bar 3-stage high pressure compressor with full maintenance schedule and
workability.
To ensure that production activities run smoothly and to work in accordance with the production plan in three
different shifts round the clock i.e. 24 hours daily.
Controlling and checking of the quality of all the items being purchased from local as well as from international
market and generating satisfactory reports of the items being utilized in our beverage plant.
Address all the maintenance work in engineering utilities and pursue a daily progress report, with complete check
and balance of required parameters.
2003 - 2005
National Productivity Organization (MOIP Govt. of Pakistan).
Assistant Manager (Enterprise Development Group.

Public & Government Sector Consultancy: Provide expert consultancy to public and government
sector organizations to enhance their working quality and productivity.
 Training & Development: Deliver training sessions on Total Quality Management (TQM) tools and
techniques for:
o General public
o Senior managers in various firms
o Enable effective implementation of TQM principles within their organizations.
 Collaboration with International Experts: Partner with international experts from the Asian
Productivity Organization (APO) and Japan to:
o Strengthen both public and private sectors in Pakistan.
o Implement advanced productivity and quality improvement strategies.
 Reporting & Documentation: Submit comprehensive reports and articles to the Ministry of
Industries regarding the productivity improvement journey and related developments.
 Management Consultancy: Offer consultancy services as a Management Consultant for various
standards and frameworks, including:
SHAMIM & Co (Pvt.) Ltd – Pepsi Cola International Mar 200 5 to Aug 2007
Multan, Pakistan
www.scl – pepsi.com
Franchise of PepsiCo Int. Produces all beverages under the brand name of Pepsi Cola including water.
Maintenance & Project Manager ( Reporting to Director Technical )
10
o ISO 9000
o ISO 14000
o TQM
o SA 8000
o Addressing quality and productivity issues for SMEs in Pakistan.
 SME Support & Coordination: Facilitate a conducive environment for SMEs to implement:
o Various management tools and techniques.
o Group-based or customized solutions tailored to individual organizational needs.
 Award Design Coordination: Play a key role in designing and coordinating the President’s
Productivity Award (PPA) and the Pakistan National Quality Award (PNQA) to recognize and
encourage excellence in productivity and quality.
 Benchmarking & Best Practices: Lead the implementation of benchmarking and best practice
networks among SMEs using a cluster approach to promote collaborative improvement and
standardization.
Management Consultants Experience in the following organizations.
Silver Lake Food, Hattar, KPK Food Industry
M/s. Leisure Textile, Lahore, Punjab Textile Industry
Body Media International, Sialkot, Punjab Textile Industry
BIAFO Industries, Hattar, KPK Detonator Industry
Metro Hi tech, Gujrat, Punjab Fan Manufacturing Industry
Thermosole Industries, Lahore, Punjab Plastic Extrusion Molding Industry

Expertise

Project Planning

Maintenance of plant plus engineering utilities

Total Productive Maintenance

Six Sigma

Total Quality Management

Plant & Process optimization

Quality Assurance & Quality Control

Languages

English

Proficient

Urdu

Proficient

Pushto

Proficient

Persian

Proficient

Hindko

Proficient

French

Intermediate

arabic

Beginner

Portfolio

Honors & awards

2004

Productivity Specialist

I got this certification from Govt. of Pakistan.
2007

IOSH

Singapore Productivity Organization
2007

Nebosh

Malaysian Productivity Organization
2008

ISO 9001-2008 Lead Auditor

Lahore Chamber of Commerce (PNAC) Pakistan National Arredation Council.
2010

ISO 14001 Lead auditor

UVAS acedemy Karachi in collaboration with PIQC (Pakistan Institute of Quality COntrol).
2011

Six Sigma - Black Belt

From International Acceredataion Council Dubai.
2004

SA 8000 & ISO 17025

PNAC (Pakistan National Acceredataion Council)

Skills

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Education

Skills

Communication

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About junaid Ali Malik

About me

Education

Masters of Business Adminstration (M.B.A).

B.Sc Mechanical Engineering

Experience

General Manager - Technical

Plant Head

Director Technical

HOD Engineering, Maintenance & Utility Department

Technical Services Manager

Maintenance & Project Manager

Assistant Manager (Enterprise Development Group.

Expertise

Languages

Portfolio

Honors & awards

Productivity Specialist

IOSH

Nebosh

ISO 9001-2008 Lead Auditor

ISO 14001 Lead auditor

Six Sigma - Black Belt

SA 8000 & ISO 17025

Skills

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