Abdul Rafay

Capital Project Lead - GSK | Ex-LCI(formely ICI) | Ex-Pfizer

Pakistan

About

As an experienced and dedicated professional, I strive to leverage my technical and analytical skills to help organizations achieve their goals. With a Bachelor's degree in Industrial & Manufacturing Engineering from NED University of Engineering & Technology, and currently pursuing an MBA in Supply Chain/Finance from Institute of Business Administration Karachi, I possess a strong academic background and a solid foundation in project management, capital budgeting, and asset management. My five-year tenure at Pfizer as an Assistant Manager Maintenance & Projects and, most recently, as an Associate Manager Capital Project & Asset Management, has equipped me with comprehensive experience in project management and capital budgeting. I have successfully led several capital projects, ranging from upgrading outdated blister machines to the development of a liquid manufacturing suite and a warehouse with controlled storage conditions. I am also adept at managing capital budgets, monitoring project progress, and liaising with cross-functional teams to ensure the timely and cost-effective completion of projects. My expertise also extends to engineering and facility maintenance, procurement, and engineering store management. I have supported the maintenance team in implementing serialization solutions, qualified and validated utilities, explored appropriate suppliers in local and international markets, and ensured the continuous supply of critical materials. My goal-oriented mindset and commitment to delivering results align with any organization's vision for financial growth and operational efficiency. I am confident that my technical expertise, analytical skills, and passion for delivering quality work will make me a valuable asset to any organization.

Experience

  • Project and Capital Lead at GSK
    May 2025 - Present · 1 yr 2 mos

  • Senior Associate Capital Projects (Additional Role of Facility Maintenance Lead) at Lucky Core Industries
    Sep 2024 - May 2025 · 9 mos

    Supported post-acquisition asset transition by validating third-party assessments and updating the fixed asset register Reported capital-in-progress status to LCI leadership after Pfizer facility takeover Managed facility maintenance within allocated budget, ensuring continuity and GMP-compliant operations Led initial planning of Volume Consolidation Project, coordinating scope, costing, and stakeholder alignment Prepared infrastructure and production suite relocation plans with strategic input from VP and senior team Coordinated layout changes with DRAP, securing regulatory alignment via technical justifications Oversaw SAP procurement, vendor management, and PO tracking for critical capital projects Pitched vertical OSD manufacturing concept to VP; developed animated workflow showcasing GMP alignment Optimized process flows and layouts to improve space use and throughput Developed and maintained site capital plans aligned with long-term strategic goals Initiated core scope of Plant Consolidation, unlocking capacity for future expansion Secured DRAP alignment and regulatory readiness for key facility upgrades Delivered key capital investments: • Established New Product Development Lab for formulation trials • Initiated conversion of psychotropic area into steroidal suite, improving segregation and compliance • Planned and initiated liquid suite to shift volume from Hawksbay and boost capacity Conceptualized vertical OSD manufacturing model with animated layout for executive review 𝐒𝐤𝐢𝐥𝐥𝐬: Capital Budgeting, OPEX Management, Project Management, Facility Maintenance, Asset Management, Engineering Stores, Equipment Lifecycle Management, Fixed Asset Register, Vendor & Contractor Management, EHS Compliance, GMP Standards, Fire Safety Systems, Utility Infrastructure, Cost Control, Stakeholder Engagement, Cross-functional Leadership, CAPEX Cash Flow Forecasting, SAP, FAT/SAT Coordination

  • Pfizer (Full-time · 10 yrs 6 mos)
    • Senior Associate Capital Projects (30% FTE Secondment – Global Supply Chain)
      Oct 2023 - Sep 2024 · 1 yr

      Led Karachi site’s capital portfolio, managing business cases, global approvals, and strategic alignment Executed $6M capital plan through cross-functional teams to enhance efficiency and capability Ensured safety, quality, and cost adherence via project and validation protocols Supported engineering and production in identifying capacity-building initiatives Maintained timelines by coordinating engineering, procurement, and validation teams Developed URS aligned with technical and commercial goals for execution and procurement Conducted feasibility, cost-benefit, and risk assessments for project prioritization Collaborated with ARUP and global teams on structural design and implementation challenges Supported leadership in proposal presentations and secured global approvals Liaised with Ministry of Health to ensure compliance and obtain regulatory clearances Installed 1MW solar system, cutting energy costs and supporting NetZero goals Commissioned 250 Ton chiller at West Wharf to ensure cooling redundancy Led tank and blister line installation to boost capacity and ensure compliance Delivered capsule and lotion lines via local vendors, improving GMP and throughput Finalized NFPA-compliant dust collector for safety and environmental standards Secondment to Global Supply Chain (30% FTE) Localized global supply chain standards by developing SOPs aligned with IMEX and GSC Enabled invoicing automation and KPI tracking via DOC for improved visibility and control Enhanced forecasting, replenishment, and execution by supporting S&OP and BFRM 𝐒𝐤𝐢𝐥𝐥𝐬: Capital Planning, Project Management, Cross-functional Leadership, Solar Projects, Utility Systems, GMP Compliance, IMEX/GSC Frameworks, CAPEX Oversight, SAP, Forecasting, KPI Tracking, URS Development, Feasibility Analysis, Vendor Management, Regulatory Liaison, DOC Automation

    • Associate Manager Projects & Asset Management
      Oct 2021 - Oct 2023 · 2 yrs 1 mo

      Led Pfizer Karachi’s Capital Project Portfolio, driving business case development, budget approvals, and governance alignment Managed a $54M multi-year capital pipeline focused on reliability, GMP, EHS, and future capacity enhancements Coordinated with regional and global teams to align funding with corporate strategy and site needs Planned annual CAPEX cash flows, ensuring timely disbursement and reconciliation with finance Oversaw PKR 800M OPEX and facility maintenance budget, aligned with monthly forecasts and business plans Supervised execution of engineering projects including solar systems, purified water, HVAC, and vertical facility upgrades Maintained Fixed Asset Register (FAR), tracking additions, disposals, impairments, and annual verifications Procured and qualified production equipment with OEMs, ensuring traceability and compliance across lifecycle Managed Engineering Stores, optimized spares, eliminated obsolete inventory, and ensured just-in-time availability Finalized conceptual and detailed design for vertical manufacturing facility with JacobsWyper, optimizing layout and space Ensured audit compliance during DRAP and internal reviews for facilities and capital execution Coordinated FAT/SAT with global vendors in Germany and USA. Executed fire safety upgrades (hydrant loop, sprinklers, pump) addressing AXAXL audit findings Installed purified water loop and expanded pallet storage via loading dock redesign Led risk-based capital prioritization with SLT, aligning investments to risk registers and strategic plans 𝐒𝐤𝐢𝐥𝐥𝐬: Capital Budgeting, OPEX Management, Project Management, Facility Maintenance, Asset Management, Engineering Stores, Equipment Lifecycle Management, Fixed Asset Register, Vendor & Contractor Management, EHS Compliance, GMP Standards, Fire Safety Systems, Utility Infrastructure, Cost Control, Stakeholder Engagement, Cross-functional Leadership, CAPEX Cash Flow Forecasting, SAP, FAT/SAT Coordination

    • Assistant Manager Maintenance and Project
      Sep 2016 - Sep 2021 · 5 yrs 1 mo

      Led site-wide maintenance and utility operations, resolving issues in HVAC, purified water, and production equipment Implemented preventive maintenance with KPIs (MTBF, MTTR, OEE) to boost reliability and reduce downtime Managed capital and OPEX budgets using ZBB tools; reported monthly to Global Capital Portfolio Management Team Developed Pfizer Karachi’s 5-year strategic capital plan with conceptual designs and cost estimates Delivered EMS automation, 25KW solar pilot, and remote SAT for serialization during COVID-19 Led Global Reliability Program and preventive maintenance optimization Deployed EAMS for digital asset management, work order tracking, and reliability KPIs Supported GMP-compliant qualification, calibration, and validation per DRAP and OEM standards Managed interim Engineering Store operations; applied ABC classification and removed redundant inventory Procured and qualified roll-on labelers remotely to enhance serialization and compliance Conducted EHS audits, supported GEMBA walks, and maintained a zero lost-time accident record Executed water and energy conservation projects to support sustainability targets Renovated QO lab to global standards; design adopted as model by Pfizer global team Reduced OPEX by 12% in 3 years through ZBB and cost control Achieved zero major findings in DRAP, HSE, and corporate audits Enabled early Punjab Tender compliance via DRAP-approved serialization Reduced QARs and investigations by over 70% through improved reliability and documentation Lowered water use by 15% through conservation measures Improved engineering store accuracy by eliminating obsolete spares 𝐒𝐤𝐢𝐥𝐥𝐬: Preventive Maintenance, Utility Reliability, GMP Compliance, Project Controls, Capital Budgeting, Reliability Engineering, EAMS, Equipment Qualification, Maintenance KPIs, ZBB, Audit Readiness, EMS Automation, Serialization, Energy & Water Conservation, Strategic Planning, Vendor Negotiation, Engineering Stores, Asset Management

  • Project Intern at Hinopak Motors Limited
    Feb 2013 - Nov 2013 · 10 mos

    *Energy Management *Analyzing the energy consumption, Reduction in CO2 Emissions. *Resource conservation, climate protection and cost savings. *Developing Strategies that increase energy efficiency often reduce operating and maintenance cost. *Minimize waste and enhance production. *Cost & Payback Calculations.

  • Internee at Afroze Textile Mill
    Dec 2012 - Dec 2012 · 1 mo

    Mechanical Maintenance Department in December 2012 -Understanding of Production process, quality Assurance and quality control measures.