Hunain Javed

Senior Production / Manufacturing Engineer with over 8 years of experience in high-volume assembly, lean manufacturing, and production leadership. Proven track record of managing shift-based teams, driving continuous improvement (5S, VSM, SMED, KANBAN), and delivering cost savings. Experienced in plant-level Health & Safety compliance, performance management, and employee relations.

Currently leading daily shift operations in a fast-paced UK production environment. Seeking a Production Manager role to lead teams, embed lean culture, and own end-to-end shift performance.

Production Supervisor - Johnsons Hotel Linen - Chester, UK

(2026-03)

• Lead daily shift operations across a 24/7 production environment, managing a team of production staff to achieve output, quality, safety, and on-time customer order completion.
• Enforce Health & Safety policies including PPE, COSHH, and risk assessments; report all near misses and accidents to HSE department.
• Track shift KPIs (output, efficiency, quality, schedule adherence) and report to Production Manager.
• Identify training needs on the shop floor and support cross-training to improve shift flexibility and resilience.
• Coordinate with engineering and maintenance teams on planned maintenance to minimize downtime and ensure smooth production flow.

Workshop Manager - Autosave Ltd - Luton, UK

(2024-07 - 2026-02)

• Supervised 5+ technicians, managing workload planning, scheduling, and quality control in an automotive workshop environment.
• Streamlined parts procurement process through vendor negotiation, reducing costs by 15%.
• Implemented a digital invoicing system, cutting administrative time by 30%.
• Increased revenue by 22% through new service packages and customer loyalty initiatives.
• Provided hands-on guidance to technicians on repair processes, diagnostics workflow, and quality standards.

Deputy Manager – Production / Manufacturing Engineer - Suzuki Motor Company Pakistan/Japan

(2015-10 - 2024-01)

• Managed a team of 50+ operators and 5 team leaders across high-volume engine and transmission assembly lines.
• Conducted annual performance reviews, managed attendance and absenteeism, led return-to-work interviews, and supported disciplinary investigations. Reduced unplanned absence by 15%.
• Led rotating shift teams across days and nights in a 24/7 operation. Managed shift handovers, resource allocation, skills balancing, and real-time production issue resolution.
• Worked closely with HR on formal Employee Relations processes including disciplinaries, grievances, and capability hearings.
• Introduced a two-bin Kanban system for engine assembly components, reducing WIP inventory by 18% and saving 12M PKR annually.
• Redesigned tooling and introduced parallel processing stations (SMED), cutting changeover time by 30% and saving 15% man-hours per engine.
• Mapped engine assembly line using Value Stream Mapping (VSM), eliminated redundant stations, and reduced floor space by 25% while maintaining output.
• Led 5S and Kaizen events reducing operator part travel distance by 40%; conducted weekly Kaizen events resulting in 20+ implemented improvements per quarter.
• Installed 15 Poka-Yoke (mistake-proofing) fixtures across assembly lines, reducing defect rates by 25%.
• Accountable for H&S compliance across the engine assembly area. Conducted weekly safety audits, enforced PPE/COSHH adherence, reported all accidents/near misses, and led monthly H&S reviews with site leadership.
• Installed light curtains and area sensors on 25+ machines, achieving zero LTIs for over 2 years.
• Developed preventive maintenance schedules for 50+ machines, increasing MTBF by 30%.
• Trained in ISO 45001 and ISO 9001 audit standards.
• Standardised 25+ ISO 9001-compliant Standard Operating Procedures (SOPs), reducing audit non-conformities by 50%.
• Developed visual SOPs and standardised work instructions to support technical learning, error reduction, and smooth model changeovers.
• Trained 50+ operators in cross-variant assembly techniques and supported ERP routing integration for accurate process control.

Sales Engineer – Heavy Duty Trucks - Nissan Motors - Pakistan

(2014 - 2015)

• Delivered technical product guidance on heavy-duty trucks and explained specifications to customers and dealership teams.
• Trained 20+ dealership staff on product features and customer handling, contributing to year-on-year sales growth.

Additional Technical Exposure - Toyota Pakistan / KTDMC / Iceberg Ltd

(2010 - 2013)

• Gained early technical exposure in Toyota Production System, CAD/CAM, CNC operations, stress analysis, and renewable energy design support.
• Developed foundational understanding of TPS, JIT, Genba, Kaizen, Poka-Yoke, CAD modelling, and engineering problem solving.

MSc - Manufacturing Management - University of Hertfordshire, UK (2024)

MEM - Supply Chain Management - NED University, Pakistan (2017)

BE - Automotive Engineering - NED University, Pakistan (2013)