Production plans that keep the line running.
I’m Syed Ahmad Kamal, former Assistant Manager PPC at Atlas Honda, where I planned a 4,650-unit-a-day motorcycle build programme across scheduling, material shortages, SAP PP and export planning, and built the Excel/VBA tools that made it faster.
- Based in
- Bromsgrove, UK
- UK work status
- Authorised to work full-time
- Seeking
- Production, materials & supply chain planning
Planning the build, protecting the schedule
Production and materials planning first. SAP, data and automation in support of it.
Production Planning & Control
Daily and monthly plans in high-volume manufacturing that account for line capacity, model mix, lot sizes, inventory and material constraints.
Materials Planning
Component availability, shortages, inventory levels and replenishment timing across around 1,100 actively monitored parts.
SAP Production Planning
Production orders, BOMs, routings, work centres, production versions, MRP monitoring, confirmations and monthly production closing, used every day on a live line.
Manufacturing Data & Automation
Excel, VBA and Power Query tools that consolidate operational data and turn repetitive manual work into decision support.
Supply Chain Coordination
Working with Sales, Production, Logistics, Materials Management, Quality, Finance, Commercial, IT and suppliers to keep production running.
Forecasting & Demand Planning
Demand analysis, moving averages, exponential smoothing, forecast accuracy and the inventory consequences of each. A developing capability, built through my MSc work.
Real photos and screenshots from my work, except SAP and Supply Chain (Unsplash: ThisisEngineering, CHUTTERSNAP).
Work done on a real production line
~1,100 parts · 60 → 5–10 minMaterial Shortage Monitoring
An Excel/VBA model that pulled five to six data sources together each day to show what is short, when it hits production and whether incoming material arrives in time. Later rebuilt as a full web portal.
View case study →
6–7 h → ~1 h · adopted as standardExport Production Planning Automation
Rebuilt a one-person export planning model around a single input, with automated lot and invoice allocation across border routes.
View case study →
450 → 540 units/day packing capacityExport Packing SAP Framework
Helped build an SAP structure for CKD/SKD export packing with packed and unpacked material states, brought packing materials under MRP and moved box assembly to an outside-processing contractor.
View case study →3,000+ parts · ~PKR 50M identifiedSafety Stock Re-evaluation
Reviewed safety stock policy across 3,000+ components by supply source, replenishment time and risk, identifying around PKR 50M of inventory that could be released.
View case study →More than a planning spreadsheet
A production schedule can look achievable until a component is unavailable. Material can look available until its quality status blocks it. An ideal sequence can clash with lot sizes or line constraints. A shortage can look critical until you count the shipment already on the road.
So I treat planning as one connected system:
- Demand
- Materials
- Capacity
- Production
- Logistics
- Data
- Decisions
That’s also why automation became a natural part of my planning work. I build tools because I understand the decisions they need to support.
Built on the shop floor, not just in spreadsheets.
I’m a mechanical engineer who moved into Production Planning & Control at Atlas Honda as a management trainee and was promoted to Assistant Manager after about six months.
Since then I’ve worked part-time at Sainsbury’s while completing an MSc in Engineering Management at Nottingham Trent University, and I’ve delivered spreadsheet and automation work for more than 200 international freelance clients.
More about meWhat managers and professors say
I had the pleasure of working with Ahmad Kamal, a dedicated and motivated professional with a strong learning attitude. He consistently demonstrated responsibility, teamwork, and a willingness to take on new challenges.
Throughout the project, Syed demonstrated strong analytical and problem-solving skills, particularly in identifying operational issues and developing practical recommendations for improving production performance.
One of Syed’s key strengths is his ability to apply theoretical concepts to real-world scenarios… His work on Gantt charts, project scheduling, and risk management was precise and showed his attention to detail.
Planning should turn complexity into action.
Open to Production Planner, Materials Planner, Production Controller and Supply Chain Planning roles in the UK.