Hamza Hanif
Operations & process engineering professional — steel manufacturing, automation, and continuous improvement
Birmingham, United Kingdom
01Key impact metrics
| +15% | Production efficiency gain from lean & 5S implementation |
| −20% | Equipment downtime reduction via preventive maintenance |
| −35% | Production wastage cut on rolling mill shear optimisation |
| +25% | Machine life extension from predictive maintenance programme |
| −12% | Cycle time reduction across production workflows |
| 2× | Awarded Best Operations/Production Engineer |
02Summary
Mechanical engineering professional with 6+ years spanning production operations, process and maintenance engineering, and heavy manufacturing across steel, cement, and infrastructure sectors. Progressed from process engineer to assistant manager at a large-scale steel manufacturer, combining hands-on technical problem-solving with operational leadership.
Currently completing an MSc in mechanical & manufacturing engineering at the University of Derby. Lean Six Sigma Green Belt certified. Comfortable working across the technical and business interface, including with international delegations and senior stakeholders.
03Education
MSc Mechanical & Manufacturing Engineering
University of Derby, United Kingdom
Sep 2025 — Nov 2026
in progress
BSc Mechanical Engineering
University of Engineering & Technology, Peshawar
Jan 2018
·About
I am a mechanical engineering professional with over six years of hands-on experience across heavy industrial sectors including steel manufacturing, cement production, and large-scale infrastructure. My career has been defined by a progression from technical engineering roles into operational leadership, where I bridge the gap between engineering capability and business outcomes.
At Frontier Foundry Steel, I advanced from Process Engineer to Assistant Manager of Operations & Production, where I directed daily production for a large-scale steel manufacturing facility. I implemented lean manufacturing and 5S principles that improved overall efficiency by 15%, and led preventive and predictive maintenance programmes that cut equipment downtime by 20% while extending machine life by 25%.
My technical toolkit spans process simulation, PLC and SCADA systems, AutoCAD, Ansys, and SAP. I am certified in Lean Six Sigma (Green Belt) and Operational Excellence with Lean Management, and I apply these frameworks to drive continuous improvement, root cause analysis, and statistical process control.
I have a proven track record of managing cross-functional teams, hosting international delegations, and translating complex operational data into actionable business insight for senior leadership. I am now based in Birmingham, UK, completing my MSc at the University of Derby, and actively seeking roles in manufacturing engineering, process engineering, maintenance engineering, and production management.
·Certifications
Lean Six Sigma Green Belt
ESTIEM
Operational Excellence with Lean Management
LSCP
Additive Manufacturing
Coursera
·Professional experience
Assistant Manager — Operations & Production
Jun 2022 — Jul 2025
Frontier Foundry Steel · Peshawar, Pakistan
- Directed daily production operations for a large-scale steel manufacturing facility, managing schedules, resource allocation, and workflow design to meet output and budget targets.
- Implemented lean manufacturing and 5S principles, improving overall production efficiency by 15% and reducing operational waste.
- Streamlined cross-departmental workflows, achieving a 10% increase in production efficiency and a 12% reduction in cycle time.
- Led preventive and predictive maintenance programmes that cut equipment downtime by 20% and extended machine life by 25%.
- Applied SPC and root cause analysis to quality issues, reducing defect rates by 10% and strengthening QA protocols per ASTM 615 and ASTM 706.
- Designed and deployed SOPs across production lines, ensuring consistent quality output and compliance.
- Hosted high-level visits from international stakeholders, including Chinese delegations and banking representatives.
- Trained and mentored 15+ production staff; awarded Best Operations/Production Engineer twice.
Process Engineer
Oct 2020 — Jun 2022
Frontier Foundry Steel · Peshawar, Pakistan
- Developed and maintained overhaul procedures for rotating equipment, using technical data and re-engineering to optimise performance.
- Collaborated with cross-functional teams including the Compressor Centre of Excellence to enhance operational efficiency.
- Maximised CCM billet-to-rebar conversion while enforcing ASTM 615 and ASTM 706 compliance.
- Identified, qualified, and managed local vendor relationships; led procurement of specialised tools and test apparatus.
Trainee Engineer
Aug 2019 — Apr 2020
Cherat Cement Company Ltd
- Executed preventive maintenance programmes for rotary and stationary equipment, maintaining operational continuity and HSE/ISO compliance.
- Generated weekly maintenance reports and coordinated follow-up actions that reduced downtime and spares unavailability.
- Planned shutdown activities to minimise unplanned downtime.
Site Engineer
Jun 2018 — Jun 2019
Maqbool Calson's JV — BRT Peshawar Project · Peshawar, Pakistan
- Managed structural erection and quality oversight for the Peshawar Bus Rapid Transit Corridor, a major urban infrastructure project.
- Delivered technical guidance to field teams and resolved on-site challenges, improving project execution by 25% against timeline and budget.
- Incorporated consultant feedback into progress plans, delivering a 12% improvement in project delivery efficiency.
·Project portfolio
Revamping of rolling mill — PLC & SCADA automation
Upgraded the rolling mill's automation systems through PLC integration controlled by a SCADA system. The objective was to fully automate mill operations including motors, gearboxes, shears, and cooling beds to enhance production capacity and operational efficiency.
Contribution
- Led integration of hardware components with SCADA software, connecting motors with gearboxes to control speed of each mill independently.
- Automated shears and programmed cooling bed to-and-fro motion.
- Managed complete installation, hardware-software integration, and testing until fully operational.
- Led a team of 22–25 people to ensure seamless automation system functionality.
Rebar quality to ASTM 615 & 706 — automated shearing
Focused on enhancing premium-quality steel bar production by significantly reducing wastage after the roughing mill, particularly addressing crobs and cobbles (irregular bar shapes). Conducted multiple trials adopting time-based and distance-based approaches to optimise the cutting process.
Contribution
- Conducted in-depth research and analysis to identify the most effective wastage minimisation method.
- Worked closely with the PLC programmer to implement both time-based and distance-based cutting control.
- Determined that the time-based approach yielded superior results by avoiding detection errors from conveyor heat.
- Tested and optimised the system to ensure minimal production loss and improved material usage.
Zigzag motion elimination & premium rebar quality
Eliminated zigzag motion caused by inconsistencies in chemical composition and mechanical issues during production, which led to physical deformations in steel bars. Integrated system values through SCADA and addressed on-ground mechanical issues related to pin roll gapping.
Contribution
- Identified pin roll gapping as the root cause through extensive on-ground inspections.
- Developed and implemented KPIs for different steel bar sizes to ensure standard adherence.
- Conducted team training to standardise the adjustment process based on approved samples.
- Integrated findings into the SCADA system to ensure all future batches were defect-free.
Installation of dog house (APC unit)
Upgraded the primary section of the Air Pollution Control (APC) unit, specifically the carbon and fumes handling system used during melting. The previous system frequently choked, causing incomplete fume absorption and unfiltered emissions. Installed a Dog House structure to fully enclose the furnace area — the first of its kind in Pakistan.
Contribution
- Project lead overseeing the entire upgrade from planning and design to installation and commissioning.
- Coordinated closely with the team to integrate the new system with the existing APC unit.
- Managed installation ensuring precise fitting and functionality.
- Troubleshot operational challenges during commissioning.
KPK first Rapid Bus Transport (BRT) system
Involved in the development of the Peshawar Rapid Bus Transport (BRT) System, the first large-scale public transport system in Peshawar. Focused on constructing mechanical components and ensuring structural integrity of bus corridors, pedestrian bridges, and key infrastructure.
Contribution
- Oversaw mechanical work during the construction phase.
- Managed installation of mechanical systems including structural steel fabrication for pedestrian bridges and mechanical fittings for bus stations.
- Ensured all mechanical installations adhered to safety and quality standards.
- Coordinated with civil engineering teams to maintain project timelines.
·Technical skills
Process & quality
Maintenance & reliability
Automation & software
Leadership & operations
·Get in touch
hamzahanif198@gmail.com
Phone
+44 7346 369866
linkedin.com/in/hamza-hanif
Location
Birmingham, United Kingdom