Sr. Plant Manager
BCI International FZE
Total years of experience :22 years, 3 Months
BAALBAKI BCI Holding SA is a leading multi-region producer of Polyester polyols (Aromatic polyester polyols, Aliphatic polyester polyols), Polyurethane systems (PU Rigid Systems, PU Footwear systems, PU flexible packaging lamination adhesive systems - both solvent less and solvent base, Polyurethane Auxiliaries release agent, and Prepolymers & coatings (Isocyanate Pre-Polymers, Polyurea coatings) with a focus on the EMEA region (Europe, Middle East, and Africa).
I am responsible for production, Planning, Installation of new equipment, maintenance, warehousing, QC, and plant HSE, leading a team of 40 employees.
I was responsible for production, planning, Installation of new equipment, maintenance, warehousing, and plant HSE, leading a team of 120 employees.
Key accomplishments:
● Reduce production down time by 30% between the years 2017-2022, with process improvement in production quality control, and SOP of production procedures.
● Reduce DPC direct production cost by 20% by reducing maintenance breakdown, reduce overtime cost, and efficiency planning.
● Consume 75% of slow-moving items within the years 2019-2022.
● Installation and commission of 12 Ton solvent less lamination reactor, 8 Ton solvent base lamination reactor, 25Ton & 15Ton rigid blenders, 30 Ton Polyester reactor, 6 tanks farm vertical each tank capacity of 75 Ton, hot oil boilers, steam boiler, cooling tower, air compressor, nitrogen generator, cold room -20°C and firefighting system.
● Supervising the construction of a hangar with an area of 2000 m² and a warehouse with an area of 5, 000 m².
● Achieving the minimum level of LTIs (Lost time Injuries) ‐ for years 2019, 2021 and 2022, enabled by risk assessments, industrial hygiene assessments, continuous improvement of work permit procedure and training.
IMEX is an Angolan company that specializes in the manufacture of plastic products under the brand name HIPO.
• LLDPE low density liner polyethylene for Rotational molding (POLIVINIL ROTOMACHINARY - ITALY) for both water and diesel tanks capacity from 200 liters till 15000 liter, cones, septic tanks, and pallets.
• PVC polyvinyl chloride (KABRA MACHINE - INDIA) twin extruder for PVC pipes production.
• HDPE high density polyethylene (KABRA MACHINE) piping in various diameters and pressures. IMEX is also one of the largest mattress manufacturers in Angola, sold under the brand SMARTFLEX. Starting from slab stock foam production (LAADERBERG CONTINUES LINE - NORWAY), metal spring production (UMIT MAKINA - TURKEY), producing a wide range of superior quality mattresses in foam mattresses, metal springs mattresses and pocket spring mattresses in various sizes.
I was responsible for production, planning, Installation of new equipment, maintenance, logistics, and plant HSE, leading a team of 80 employees with 11 different nationalities.
Key accomplishments:
● Reduce production waste by 15% in the plastic plant HIPO, by enhancing the operation procedure and applying preventive maintenance schedule.
● Zero waste in plastic plant HIPO by recycling all defective produced items.
● Reduce DPC direct production cost in the mattress plant SMARTFLEX by 30% by reducing maintenance breakdown, reduce overtime cost, increasing labors efficiency and improving production layout.
● Supervising the construction of a new mattress warehouse with an area of 3, 000 m².
● Participating in the installation & commissioning of new ERP system- Microsoft dynamics GP green planes, also installation for barcode system in the mattress plant.
TECHNOPACK is the leader company in Syria for manufacturing corrugated cardboard suitable for wide range of packaging uses with all needed types of flute B, C, D, E, multiplied BC, BB (BHS line Germany). Converting and printing these boards by high quality printing machines (Martin machines France) up to 5 colors with different dimensions applying packaging solutions for packaging wide range of different products such as medicine, food, fruits, detergents….
I was responsible for production, planning, and maintenance.
Key accomplishments:
● Reduce production waste by 4%, by enhancing the operation procedure and applying preventive maintenance schedule.
● Participating in the installation & commissioning of new ERP system- OM PARTNERS (corrugated and solid board system).
BAALBAKI group is one of the largest Polyurethane producers in the Middle East, producing polyurethane, Polyesters, Unsaturated Polyester, Polyurethane adhesives, Polyurethane release agent, and Polyurethane colorants.
Production Manager - Polyurethane System House Plant Oct 2010 - Jun 2012
I was responsible for production, planning, maintenance, and plant HSE, leading a team of 240 employees.
Key accomplishments:
Achieved 25% improvement in production capacity through disciplined implementation of manufacturing policies.
● Achieved massive improvement with slow moving stock reduction 56%
● Improved productivity and efficiency through reducing overtime by 40%
● Improved product quality by reducing the percentage of rejects from 18% to 7%
Production Manager - Polyurethane Pigments & Adhesives Plant Apr 2006 - Oct 2010
I was responsible for production, planning, maintenance, warehousing, and plant HSE, leading a team of 40 employees.
Key accomplishments:
● Achieved 35% improvement in production capacity through disciplined implementation of manufacturing policies and efficient planning.
● Achieved massive improvement with slow moving stock reduction 86%
SMS (Syrian Micro Systems) is one of the largest CD manufacturing companies in the Middle East ● Products categories are STAMPERS: which is a mineral Nickel archetype manufactured by electroplating for a glass master in bath includes Nickel ions), CD-R (Green dye with silver layer), CD-ROM, DVD5(with copper layer), and DVD9.
I was responsible for quality control and product inspection/testing, Preparation of dye solution ULTRAGREEN MX with DMH, DBE solvents, restoration for the dye solution using double beam spectrophotometer and gas chromatography, and for mastering unit.
I’ve participated in the plant construction, equipment installation and commissioning.
Teaching Chemistry for high school students