مجدي سليمان

Conferring with management personnel to establish production and quality control standards, develop budget and cost controls, and to obtain data regarding types, quantities, specifications, and delivery dates of products ordered.
• Planning and directing production activities and establishes production priorities for products in keeping with effective operations and cost factors.
• Coordinates production activities with procurement, maintenance, and quality control activities to obtain optimum production and utilization of human resources, machines, and equipments.
• Reviews and analyzes production, quality control, maintenance, and operational reports to determine causes of nonconformity with product specifications, and operating or production problems.
• Develops and implements operating methods and procedures designed to eliminate operating problems and improve product quality.
• Revises production schedules and priorities as result of equipment failure or operating problems.
• Consults with engineering personnel relative to modification of machines and equipment in order to improve production and quality of products.
• Review production orders or schedules to ascertain product data such as types, quantities, and specifications of products and scheduled delivery dates in order to plan department operations.
• Estimate the material and human resources needs to meet planned production schedules.
• Liaise with different departments and companies including suppliers, Purchasing manager and other concerned parties to prevent any potential delays or issues.
• Inspect machines and equipment to ensure specific operational performance and optimum utilization.
• Ensure that the products meet the established quality guidelines and standards of AMERICANA and are on time..
• Develops capital equipment justifications for machine tools and technology to improve quality, cost, and cycle times.
• Maintain up-to-date knowledge of health and safety standards and strategies.
• Suggests changes in working conditions and use of equipment to increase efficiency of Workshop or work crew.
• Supervise and motivate team of workers and reviewing the work performance of subordinates.
* Supervises machines preventive maintenance programs. Recommends machines modifications if needed. Ensures smooth supply of spare parts.
* Prepares annual manpower plan. Makes sure all vacant positions are filled in coordination with personnel Manager.
* Coaches and trains production staff. Prepares on job training programs. Evaluate performance of staff, recommends promotion, additional training or termination.


Main achievements:-
•Evaluating performance of current team & Production lines and Utilities.
•Construction of production KPI’s Depends on 5 categories Quality, Delivery, Cost, Safety, Morals.
•Establishing Production areas Dash Boards to review the QCDSM for each line on monthly basis.
•Reviewed the current KQI’s & QC inspections and product specs and reconstructed new statistical process control sheets and calculation of standard deviation and process capability.
•Reconstructed & fixed the line manning depending on TAKT time and time motion study.
•Calculation of Production lines capacities per each SKU & OEE.
•Setting standard for production lines productivity.
•Establishing value stream mapping for each product family to assure on JIT Operation.
•Establishing a firm system for quick change over time for both dies & tools.
•Training of section heads & team leaders on how to use the new production check sheets and how to calculate production KPI’s in their work stations.
•Decreasing the total factory labors from 672 to 512 labor.
•Decreasing the total lost time from 17% to 3.2%.
•Increasing the productivity man/hour from 4.2 MB to 7.4 MB.
•Increasing lines daily utilization up to 96.8%.
•Decreasing factory overtime about 54%.
•Start launching of 5S’s implementation process in all factories.
•Troubleshooting of chronic problems and setting corrective actions.
•Application of OCR program on all production lines activities.
•Setting of Monthly OPL’s & Cost saving Activities as a KPI’s for area managers.
•Started wide spread implementation of 7 wastes elimination program in all production areas.
•Establishing of IFT-In Factory Training Courses.

. Nada dairy ( 4 Factories for dairy products and juice & 3 factories for PE &PET

checking of the raw material like Raw milk and powder milk and fruit concentrates and the ingredients like all stabilizers, emulsifiers, flavors and colors before going to use in production or up on its arrival in the company to make sure whether the raw material is acceptable or not for the final production and reporting to the plant manager.
•Manage staff consists of 350 persons (Engineers, Technicians, labors )
•Responsible for the new product development by working together with the highly experienced and competent team of Quality Manager, Marketing Manager.
•Responsible for the production during the mix preparation, its processing, and filling and till the product goes to the market to avoid any kind of deviation from the set standards of any kind of quality aspect and make sure to reach the product to the consumer at the highest possible quality & taste.
•Leader of Trouble shooting team comprising of QC Laboratory, Production and Maintenance personnel for a systematic troubleshooting. Responsible for maintaining all the required documentation of each and every product being packed in UHT.
•Gained very rich experience with the testing methods and systems of very wide range of raw material as the company is producing all its milk, juices and drinks based on recombining the ingredients like fruit concentrates, milk powder and, butter, frozen cream and other needed ingredients such as stabilizers and emulsifiers.
•7- Applying the Data base program (SAP 710).
•Defines and Implements the company policies and procedures and provides leadership, coaching and assurance in the application of production policies.
• Continual improvement by reducing customer complaints and implementing preventive actions for avoiding recurrence of the complaints.
•Developing HACCP for new/ existing plant / process and ensuring implementation & adherence through subsequent audits.
• Highlighting critical issues by executing GMP audits & providing corrective/ preventive action plan.
• Implemented successfully valve check system as a proactive approach in avoiding post processing contamination as well as online contamination.
• Identified issues in critical areas and provided a window of potential improvement to production engineering by focusing on recurring equipment issues to implement corrective actions.
•Investigated issues in long life juices and milk, yoghurts, desserts as well as fresh milk, laban and juices.
•Corrective action audits to prevent recurrence of issues towards qualitative improvement and overall improvements in management defined parameters.
•Highlighting critical issues by executing extensive GMP audits in filling and processing areas & providing corrective/ preventive action plan.
•Trainings and presentation to other departments on GMP, complaint reduction and personal hygiene as well as induction to new employees on personal hygiene and code of conduct.
•Working with department managers to ensure the implementation of corrective actions on GMP audits, major non-compliance and product complaint.
•Developing PRE-HACCP for project activities wherein the movements and activities during the project and associated hazards are highlighted and rectified to avoid any hazard (micro/physical/chemical) to the food.
•Troubleshooting for major non-compliances as well as product quality issues and providing corrective actions to prevent recurrence of the issues..
•Knowledge and Experience of UHT based process, Combibloc, Tetrapac machine running and Aseptic packaging