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Food Safety · Lean Manufacturing ·
OEE · Data Analytics

Md. Hasibul Hasan, Manufacturing & Operations Leader

Data-Driven Process Excellence

20+ years leading plant commissioning, Lean Manufacturing and Food Safety Systems (HACCP, FSSC 22000). Now building data-driven, automation-ready operations with Power BI, SQL and Python.

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Years in FMCG & Process Ops
20+
Plants Commissioned (100–3000 TPD range)
100–3,000TPD
Capacity Gain via Lean/OEE
25%
Engineers & Operators Trained
150+

Delivered zero major non-conformances across Coca-Cola, Nestlé & Transcom supplier audits.

About Me

20+ Years Turning Plants Into Reliable, Data-Driven Operations

I am a Manufacturing & Operations Leader with over 20 years of progressive leadership across FMCG sugar and continuous process manufacturing, specializing in plant commissioning, operational excellence, OEE improvement, cost optimization and cross-functional leadership. As Deputy General Manager (Plant Head) at PRAN Group, I led the commissioning, stabilization and commercial start-up of a 100 TPD food-grade liquid sugar plant, directing Production, Maintenance, Utilities, Engineering, Warehouse and Quality with full operational accountability.

Earlier, as Head of Quality Assurance at City Sugar Industries (3,000 TPD & 2,000 TPD refinery), I built HACCP, FSSC 22000, ISO 22000 and ISO 9001 systems from the ground up and maintained zero major non-conformances across nine years of Coca-Cola, Nestlé and Transcom supplier audits. I am currently a Senior Chemist (Laboratory Systems & Technical Advisory) on a World Bank-supported DPHE water quality project, and have strengthened my leadership toolkit with Data Analytics (Power BI, SQL, Python), PMP and Lean Six Sigma Black Belt preparation, which I applied together with my team to complete automation initiatives across plant operations.

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Md. Hasibul Hasan

Quick Facts

Experience
20+ Years
Current Role
Senior Chemist Consultant, DPHE (World Bank)
Industry Background
FMCG Sugar & Process Mfg.
Education
M.Sc. Applied Chemistry, Univ. of Rajshahi

Certifications & Training

  • HACCP
  • FSSC 22000
  • ISO 22000
  • ISO 9001:2015
  • PMP (Exam Prep)
  • Lean Six Sigma Black Belt (Exam Prep)
  • Power BI · SQL · Python
  • ISO/IEC 17025 & GLP

Core Competencies

One Synchronized System: Culture, Lab & Data

If the data isn't real, the lab can't perform. If the lab doesn't perform, manufacturing can't either. Two frameworks I've developed keep this chain honest, and both are built on the same foundation: people and workplace culture.

  1. LFS-HMS™

    Lean Food Safety: Human Management System

    Builds the workplace culture that makes lab & compliance data real

  2. Manufacturing Excellence

    OEE & Lean Execution

    Runs reliably only on trustworthy lab & process data

  3. DA-HMS™

    Data Analytics: Human Management System

    Turns manufacturing data into decisions people act on

  4. IWMS™

    Integrated Waste Mgmt. System (Solid & FSM)

    Extends the same human-systems discipline to public health & environment

↻ Insights feed back and reinforce the culture at LFS-HMS™, making this a continuous loop across four domains rather than a one-way line

LFS-HMS™

Lean Food Safety: Human Management System

A people-first operational framework that embeds Lean Manufacturing discipline into Food Safety systems (HACCP, FSSC 22000, ISO 22000). It works on workplace culture and human habits first, because food safety and lean efficiency only hold up when the people performing them, every shift, are consistently trained, engaged and accountable. Built manpower capability through Kanban scheduling and machine-ownership programs (150+ engineers and operators trained).

DA-HMS™

Data Analytics: Human Management System

A framework that connects shop-floor and lab data to decision-grade analytics (Power BI, SQL, Python) through human adoption, not just dashboards. Data only improves manufacturing when trained, accountable teams actually act on it, closing the loop back into daily culture.

IWMS™

Integrated Waste Management System (Solid Waste & FSM)

Extends the same human-centered systems thinking beyond manufacturing. It applies structured, standards-aligned waste management (solid waste and Fecal Sludge Management) to protect public health and the environment, and is currently practiced through World Bank-supported DPHE water quality and sanitation projects.

Core Leadership Competencies

  • Plant Commissioning & Start-up Management
  • Large-scale Continuous Process Manufacturing
  • Production Planning & Capacity Optimization
  • Project Planning, Scheduling & Resource Management
  • Cost Leadership & Operational Excellence
  • Automation, PLC & Process Control
  • Preventive Maintenance, TPM & Equipment Reliability
  • Lean Manufacturing, OEE & Continuous Improvement
  • Cross-functional Leadership & Team Development
  • Engineering, Utilities & Contractor Management
  • Quality, Food Safety & Regulatory Compliance
  • Process Safety, Risk Assessment & Technical Governance
“Quality is not an act, it is a habit.”
Aristotle

Professional Certifications & Training

Continuous Learning, Applied on the Plant Floor

Formal training across Food Safety, Quality Systems, Lean Operations, Safety and Data Analytics, from 2009 to today.

  • Internal Auditing Training (FSSC 22000)

    Strotus Corpsol

    Apr 2015

  • Implementing ISO 9001 Quality Management System

    Bangladesh Institute of Management

    Mar 2014

  • Quality Control & Management of Industrial & Drinking Water

    Training Institute for Chemical Industries (TICI), Narsingdi

    Jan 2009

  • Leadership Certificate in Managerial Communication (LCMC)

    IBA, University of Dhaka

    Dec 2017

  • Lean Six Sigma Black Belt Course

    bdjobs Training

    Nov 2018

  • Understanding Food Regulations & Food Labeling

    Coursera / University of Illinois

    Jan 2026

  • Navigating U.S. Food Regulations: Safety and Enforcement

    Coursera / University of Illinois

    Jan 2026

  • Certified Data Analyst

    Data Solution 360

    Aug 2025

  • Fire Fighting, Prevention, Rescue & First Aid Training

    Bangladesh Fire Service & Civil Defence Directorate

    Sep 2015

  • Applied Health, Safety & Environment (HSE)

    bdjobs Training

    Sep 2012

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Highlighted Achievements

Proof, Not Just Promises

100 TPD

Greenfield to Commercial Start-up

Commissioned and stabilized a 100 TPD food-grade liquid sugar plant at PRAN Group, building integrated Production, Maintenance, Utilities and Quality systems from day one.

Zero → Full

HACCP & FSSC 22000 Built From the Ground Up

Led HACCP, FSSC 22000, ISO 22000 and ISO 9001:2015 implementation from zero to full compliance across multiple sugar manufacturing operations, covering FSMS documentation, CCP monitoring and internal audit frameworks aligned with GFSI standards.

+25%

Capacity Gain, Zero Capital Investment

Improved effective plant capacity by over 25% through Lean Manufacturing, OEE improvement and bottleneck elimination, with no new equipment required.

6 Months

Reactive to Reliability-Centered Maintenance

Transformed maintenance from reactive firefighting to preventive, reliability-centered practice within six months, cutting unplanned downtime across production and utilities.

Recent Insights

Fresh Off the Line

Food Safety & QualityবাংলাPublished Updated

HACCP শেখা: খাদ্য নিরাপত্তার জন্য একটি সহজ গাইড

HACCP শেখার একটি সহজ গাইড, বাস্তব অভিজ্ঞতা থেকে লেখা: ৭টি নীতি, সাধারণ ভুল, এবং Codex Alimentarius, ISO 22000 ও FSSC 22000-এর সাথে এর সম্পর্ক।

Food Safety & QualityPublished Updated

Learn HACCP: A Beginner's Guide to Food Safety

A beginner's guide to HACCP, written from 9 years of real MNC audit experience: the 7 principles, common mistakes, and how it connects to FSSC 22000 and ISO 22000.

Food Safety & Quality

Audit-Ready Workplace Culture: From Compliance to Risk Ownership

How workplace culture shapes HACCP audit outcomes. Learn how leadership, validation, and internal audits build real food safety risk ownership.

View all insights

Get In Touch

Let's Talk Operations, Data or Your Next Hire

Open to manufacturing leadership roles, technical advisory engagements and consulting on Lean/OEE, Food Safety Systems and data-driven operations. Based in Bangladesh, available for opportunities locally and abroad.