Shoaib Ismail

Engineering leader with 15+ years of experience in Pharmaceutical Manufacturing, Utilities, and Automation, managing large-scale maintenance operations, engineering teams, and CAPEX projects. Proven record of reducing equipment downtime by 50%, improving OEE from 58% to 76%, and managing 150+ production machines in GMP-compliant environments. Expertise in OSD, Sterile, MDI, DPI, BFS, and packaging facilities, SAP PM implementation, asset reliability, and engineering strategy.

Strong leader with responsibility for 39-member engineering teams and PKR 264 million (~USD 1M) annual engineering budget.

Sr. Manager Manufacturing Maintenance, Instrumentation & Controls - Getz Pharma Private Limited - Pakistan

(2023-01)

• Manage maintenance of 150+ critical production machines across OSD, Sterile, MDI, DPI, BFS, and packaging facilities.
• Lead engineering strategy for production, QC laboratories, and warehouse operations with 39-member multidisciplinary engineering team.
• Reduced plant downtime by 50% and improved OEE from 58% to 76% through predictive maintenance, reliability engineering, and RCA programs.
• Manage annual OPEX budget of PKR 264 million (~USD 1M) for production equipment and utilities.
• Increased machine availability by 20% through implementation of predictive maintenance and critical spare parts planning for granulation, compression, and coating equipment.
• Reduced changeover time by 40% using SMED techniques while maintaining strict cleaning validation and cross-contamination controls.
• Led OEE loss mapping aligned with the Six Big Losses model, improving plant-wide OEE by 18% within one year.
• Improved Mean Time Between Failures (MTBF) by 22% by strengthening autonomous maintenance practices and operator skill development.
• Implemented real-time OEE monitoring dashboards.
• Supported regulatory audits (USFDA / MHRA / WHO) by ensuring documented OEE improvements aligned with data integrity (ALCOA+) principles.
• Increased capacity utilization by 17% without additional capital investment by eliminating bottlenecks in Compression and Blister Packaging Line.
• Plan and schedule preventive, corrective, and predictive maintenance tasks for over 150 critical assets using SAP PM Module.
• Hands on experience of maintaining, OSD Manufacturing, Packaging, Sterile, MDIs, DPIs, Sachet Filling & BFS Plants.
• Managing and Operating Engineering Warehouse activities for Production Machines as well as Utilities.
• Prepare OPEX & CAPEX Budget for upcoming equipments.
• Looking after the Condition Based Monitoring of Production Machines and make strategies to minimize machine stoppages.
• Work as Subject Matter Expert for the Implementation of SAP PM Module for different plants of GPPL.
• Ensure safety, health, risk and environment control are fulfilled and maintained in workplaces.
• Perform Factory Acceptance Test and Site Acceptance Test within and outside Pakistan.
• Perform FAT & SAT for upcoming equipments and provide report as per URS.

Manufacturing Maintenance Engineer/Manager - Getz Pharma Private Limited - Pakistan

(2015-01 - 2022-12)

Assistant Manager Maintenance - Beltexco Limited (Midas Safety) - Pakistan

(2013-01 - 2015-12)

• Developed and executed plant maintenance plans improving equipment reliability and production consistency.
• Executed major projects including chemical storage tanks, silos, piping systems, and pumps installations.
• Managed maintenance operations, spare parts inventory, budget, and compliance with safety regulations.
• Manages the plant's operations, maintenance, projects, and departments including Spare parts, inventory, budget, and compliance with environmental and Safety regulations.
• A Multi skill SAP professional with Technical and Functional Expertise. Extensive Practical knowledge of SAP PM (Plant Maintenance) Module. Sustain & Improves Reliability of Plants Operations, Maintenance & System Documentation.

Associate Manager Maintenance - Hilal Confectionery Pvt Limited - Pakistan

(2012-01 - 2013-12)

• Assisted in erection and commissioning of Cup Cake production line and utility systems.
• Implemented ISO 9001 and ISO 22000 documentation and food safety systems.
• Developed SOPs for boilers, chillers, RO plants, and power systems.
• Made work instructions for utility department like BOILERS, CHILLERS, R/O PLANT, POWER HOUSE.

Master of Engineering Management - Energy & Plant Management - NED University of Engineering & Technology

Bachelor of Mechanical Engineering - Mechanical Engineering - NED University of Engineering & Technology