Plant Manager
Zamil Group
Total years of experience :16 years, 6 Months
Establish new business development department with responsibilities of:
o Develop and standardize all standard and special products.
o Develop and standardize all operations and processes.
o Lead the improvement projects in terms of productivity increase, process optimization and space and machinery utilization.
o Create new system for production efficiency, monitoring and follow up.
o Implement basic lean concepts and provide training for the teams.
o Update the drawing office to be a designing office by implementing new techniques and software.
Create a new planning department and create control tools for production
Assigned as a Project Manager for implementing a full warehouse solution for raw materials and finished goods.
Assigned as a Project Manager for transferring the plant to a new location.
Responsible for Producing more than 15 different types of products.
Responsible for fulfilling and delivering the weekly customer demands with standard quality and high efficiency (95%).
Improve productivity by 35%.
Decrease the cost of the product by 15%.
Control and maintain the WIP value & the material flow.
- Leading segment with more than 250 operators & 15 from functional departments (Engineering, Quality, Procurement, Logistics, Planning, Production Technology).
- Produce more than 10 different types of products with different types of processes.
- Responsible for fulfilling and delivering the weekly customer demands with standard quality and high efficiency (120%).
- Review and update the capacity plan reflecting number of operators, required production and testing facilities, required space and the KANBAN for production materials.
- Control and maintain the WIP value & the material flow.
- Implement and monitor the production KPI’s.
- Implement the lean manufacturing tools (KATA and 5S).
- Ensure the implementation for continuous improvement of our performance in the entire value added process according to the principles of continuous process optimization.
- Leading Team with Liaising to other Dept. (Planning, Logistics, Quality, Production and Technical service) to succeed in fulfilling the milestones of the Current Build Phases & future models of our main customer (JLR) Jaguar / Land Rover.
- Liaise with (JLR), Egypt and UK teams to guarantee continuous progress of project phases till the launch of volume production.
- Manage several projects simultaneously, each running at a different phase ensuring the management of all aspects of the project.
- Ownership of the project since its acceptance, and being a member of the project initiation phase.
- Main contact person with the customer during the project life time.
- Prepare the schedule and planning of the project to meet the customer requirements.
- Control the project in terms of milestones, dependencies and actions.
- Follows all Customer specific requirement, Quality Standards & processes.
- Manage the project risks and issues.
- Reports the project to different stakeholders (customers, management and senior management team).
- Dealing with Production day to day activities (finding an alternative for shortage material, member of a cross function team to solve any concerns from the customer, member of a cross function team for (CIP) Continues Improvement).
- Internal Auditor on other departments all the year & an Engineering representative during the TS Audit.
- Support Jaguar & Land Rover UK 'On site Support', for introducing new samples as I am one of the team responsible for Model years sample builds.
- monitored the daily production on the shop floor
- supervised the process flow
- prepare the weekly production plans for each machine
- monitored the timings for each process & the process tack time
- prepare weekly reports for production weekly review
- install new machines
- searching for suppliers for materials & machines
Design the process flow for doors, windows and aluminum walls
Coordinate cutting, coating, painting & assembly departments performing multiple activities to ensure the pieces come together at the right time to complete the product while managing deadlines and resources
Prepares timing plans, co-ordinates the activities necessary to ensure the successful introduction of products
Manage day-to-day activities of production
Graduation Project: Design and Manufacturing Fatigue Testing Machine Controlled and Monitored by a Programmable Logic Controller. Grade: Very Good. Training Project: Design and Implement a Mechanism of handling system of one off EZZ Steel Furnaces.