Plant Manager
National Oil Varco
Total years of experience :21 years, 4 Months
• Responsible for project management during planning till commissioning
• Responsible for production of Valves & chokes and exporting them worldwide
• Responsible for project management during planning till commissioning
• Responsible for product transfer from USA to Saudi Arabia; know-how and start up including recruitment and training
• Working on all legal necessities to make the factory up and running
• Approving the facility to be approved within ARAMCO as approved vendor .
• Certifying the plant for API; API Monogram 6-1 from American petroleum institute
• Building a QMS for the Plant and being certified as ISO 9001;14001; OSHAS 18001.
• Responsible for development of all departments in the plant by working on KPI`s and performance measurement.
• Managing all financial issues related to the plant (P & L; budget; quarter sales & deliveries; setting future production plans according to forecasted sales plans.
• Implementation of lean concept make saving increasing margins of profit.
• Implementation of SIM (short interval management) concept & maintaining its effectiveness.
• Monitoring daily activities within factories & conducting internal audits
• Supply chain management and coordination with Overseas Team for supply chain & procurement department.
• Study of new products & feasibility study
• Cooperation with sales & marketing team to achieve yearly targets and monitoring OTD quarterly and monthly
Responsible for operations development & quality & safety activities for the whole group
. implementation of TQM system and certifying the company for ISO 9001
. Operations & processes monitoring a uniform flow; documentation of all processes & standardization .
. Responsible for development of processes;products R&D; machines;productivity; machine utilization
. Responsible for shared services departments Maintenance dept. supervision; implementation of preventive maintenance plan; safety; QA/QC
. Managing all financial issues related to the operations plant ( asset management project)
. Supervision for safety for all the factories & the projects
. Bids study & special orders production & delivery terms.
. Analysis of VOC (Delivery on time; productivity, efficiency; waste mgmt.; quality index).
. Building up company strategies for operations side supporting marketing & sales vision
. Feasibility study for all new products & partnership’s
.Responsible for optimal utilization of space & machineries
.ERP Project Implementation Manager with Orion 10.6
.Implementation & Analysis of NCR & impact on business; monitoring corrective actions
.Study of new products & feasibility study
. cooperation with sales & marketing team to achieve targets complying with strategies
. introducing performance management system with HR dept.( KRA`s;KPI;….etc)
. Introduction of Operational excellence frame work to have a solid turnaround for the company through a plan containing ( TQM-lean manufacturing-operations excellence-Buisness excellence)
• Operations and processes standardization monitoring a uniform flow; documentation of all processes and drawing vsm for all processes monitoring & analysing points for improvement
. Orion ERP implementation project manager for ZAH
. Creation of maintenance department and assuring uniform operation through maintenance supervision; implementation of preventive maintenance plan.
• Managing decision making for all financial issues related to the operational day to day activities in plants.
• Supervision for safety departement of all the factories and the projects and assuring a safe working environment.
• Bids study and special production orders and delivery terms.
• Analysis of VOC (delivery on time; productivity, efficiency, waste
monitoring; quality index).
• Building up company strategies for operations side supporting marketing and sales vision.
• Feasibility study for all new products and partnership’s
• Responsible for optimal utilization of space and machineries.
• Set measurable targets and track/drive progress for all sites.
• Provide leadership direction and governance for all companies/sites at national level on health, safety and environment in compliance with statutory laws and alignment to company operational practices.
. Building up buisness oriented culture by identifing both the routine and non-routine tasks that this employee has to perform in order to achieve the KRA identified.
CFC Development Manager & Saf feed factory Manager
- Responsible for 5 factories (360 operators in three shifts)
1. Feed factories Development
2. Plant manager for Saaf Feed factories
3.Responsible for development of saaf-plant in all fields
- Lean implementation achieving results after 15 month.
- Reporting to the operational Director and performing all required reports showing facility performance
-Managing all financial issues related to the plant(P&l;budget; quarter sales & deliveries;setting future production plans according to forecasted sales plans
- Supervise & guideline work organization to achieve company targets.
- Prepare a complete cycle of performance evaluations & improvement technique
- Identify performance deviations and develop action plans for correction.
- Implementation of SIM (short interval management) concept & maintaining its effectiveness.
- Introduction & implementation of 5 S & training; monitoring to make it take place
- enhancement of factory productivity, Quality, efficiency
-Responsible for three factories (400 operators two shifts)
1. Metal sheet & copper manufacturing factory;
2. Low voltage compartments & panels assembly production factory
3. Meduim Voltage compartments & panels assembly production factory
Types of product (SM6; Ronex; Fleur 200; 300; Imcset).
- Supervise & guideline work organization to achieve company targets.
- Conduct regular performance evaluations & internal system audits.
- Identify performance deviations and develop action plans
-implementation of SIM (short interval management) concept
-Implementation of 5 S & training;monitoring to make it take place
- transfer of all the three factories & startof production in the new factory at Badr city.
-Responible for all the maintinance activities & break downs
-analysis of break downs & developing actions to make sure to be not repeated.
-Reporting to the operational Director
-Introduction of Kanban & setting effective information flow .
- coopration with other departements to reduce the wastes (time;effort;scrap;material) by implementation of scrap controlProject .
-Responsible for the safety procedures implementation & hazardous material within the working premises
-Development & training of Production work force( technicians;foremen;engineers;Manager for each factory)based upon periodic evaluation & assesment .
-Responsible for all maintenace activities around the plant & the production area
-Perform preventive maintenance plans & make sure the measures & procedures are followed
-Responsible of the plant from fence to fence & all day to day activity of whole shift to meet company expectations by:
-Supervise & guideline control labor as well as training and up grading line inspectors.
- Resources allocation for the line to assure max utilization present manpower
- Evaluation of the finished product through regular audits according to Guardian Procedures.
- Ensure timeous delivery of product
- Ensure correct usage of parts and materials
- Ensure max. Resource utilization
- Set objectives, prioritize and allocate resources to meet objectives
- Manage the production scheduling and line balancing process
- Daily communication with team regarding production requirements
- Supply correct quality and quantity of product timeously and to the correct specifications
- Control and record scrap weekly& perform analysis for high figures.
- Consistent achievement of daily, monthly and weekly targets
- Monitor and control expenditure to set budgets
- Manage and utilize subordinates to ensure that quality and quantity objectives are achieved
-Supporting HR dept.through training of other departement candidates by performing managment training programs;also by assisting in holding interviewes & in employee yearly evaluation programs.
-Performing Regular internal audit as certified auditor according to audit plan to maintain company targeted level of performance
- Production scheduling according to sales plan orders.
- Supervise & guideline work organization to achieve company Targets
-Training staff through the company training center - Organize, manage and control WIP stock and inventory level checks
- Develop and implement production plans
- Achieve daily, weekly and monthly targets as per schedule.
- Communicate technical, quality and other problems to relevant parties
- Identify performance deviations and develop action plans
- Ensure timeous delivery of product
- Ensure correct usage of parts and materials
- Ensure max. Resource utilization
- Set objectives, prioritize and allocate resources to meet objectives
- Manage the production scheduling and line balancing process
- Daily communication with team regarding production requirements
- Supply correct quality and quantity of product timeously and to the correct specifications
- Control and record scrap weekly& perform analysis for high figures.
- Consistent achievement of daily, monthly and weekly targets
- Monitor and control expenditure to set budgets
- Manage and utilize subordinates to ensure that quality and quantity objectives are achieved
- Conduct regular performance evaluations
- Ensure time and resource allocation among staff in accordance with the development plan
- Empower and continuously motivate team
- Provide appropriate information and feedback to employees timeously, accurately
- Attend relevant meetings regular and provide input as required
- Liaison with production planning, sales, and process and development departments
- Ongoing liaison with the quality department and continuous monitoring and enhancement of quality standards
- Monitor and manage machinery maintenance in liaison with Technical Services
- Adhere to and enforce relevant legislation and policies
- Ensure that the highest degree of safety and safe working practices are maintained
- Assist and support line management in problem solving
-Production scheduling according to sales orders.
-Training the factory manpower before production on the machines in the factorty
- Training the stores team on MRP, Logistics techniques, BOM, FIFO techniques, how to organize racks, shelf life.
-Supervise & guideline control labor as well as training and up grading line inspectors.
- Resources allocation for the line to assure max utilization present manpower
- Investigation of assembly problems and line faults analysis.
- Establishing of working procedures, work instruc6tions and control checking formats.
- Evaluation of the finished product through regular audits holding presentations to demonstrate inspected faults.
- Establishing of corrective action for major & repeated faults.
- Monitoring production line outputs through regular audits, analysis through extracted samples analysis
-Participation with Design /Quality Department to solve design related problems.
-All factory installtion, recruitment, production facilties preperation, infrastructure revision & correction.
-launching production in may 2004
*Preperation for Egypt factory :
1.m/c commissoning &training
2.manpower calculation /allocation & recruitment
3.Factory lay out & m/c`s allocation according to production flow
4.Preperation for materials (productive & raw from local egyptian market / UAE & others
- Check final product according to D.C. specifications.
- Supervise & guideline control check as well as training and up grading line inspectors.
- Investigation of assembly problems and line faults analysis.
- Establishing of working procedures, work instructions and control checking formats.
- Evaluation of the finished product through regular audits according to APA Mercedes Specs., holding presentations to demonstrate inspected faults.
- Establishing of corrective action for major & repeated faults.
- Approve, Assure completion of documentation for product release.
- Participation in quality management team for ISO 9001, VDA 6.1, ISO
TS-16949 Certificates preparation.
- Managing quality team in component operation factory to achieve company
Planned targets, objectives.
-Monitoring production line outputs through regular audits, analysis
through extracted samples analysis
- Participation with Engineering section to solve design related problems
-Commissioning & installation of new CNC; Measuring M/C`S&devices from Germany
-supervision &operation/maintenance of highly sophisticated 3d measuring machines for brake disc CNC machining.
-using Q-stadt software to analyse data from line feed back to line daily to adjust machining process in all stations individually according to data analysed
ISO TS 16949 implementation & effect on buisness & other suplliers
awarded by completition of my graduation studies by half fees by getting 93%