Operations Manager
EGMA Optical Supplies
Total years of experience :15 years, 11 Months
• Business team member accountable for providing strategic insights for decision making
• Responsible for Production, Logistics, Customer Service, Continuous Improvement & Maintenance reporting to the Vice President
• Responsible for leading, developing & engaging 50 direct reports
Key Achievements:
• Implemented new smart shifts which improved lead time by 80% achieving delivery withing 24 hours & 30% less customer complaints while
• Built mutual benefit scheduling increasing the overall morale of 4 different departments while maintaining productivity
• Designed & implemented production, maintenance, logistics & customer service KPI’s
• Re-designed the factory layout for lean, saving 40% of material & people movement
• Reduced complaints by 83% & improved Safety score by 170% through process redesign
• Re-designed the production shift pattern & ways of working to reduce the lead time by 80%
• Built a full product costing model & designed an automated tool to easily update it when necessary
• Designed & deployed full logistics, factory, customer service, ordering & maintenance KPIs with their continuous monitoring & reporting system
•Specialized in Lean business transformation & management consultancy, design & implementation
•Structured & managed projects including teams up to of 30 employees
•Facilitated & conducted qualitative/quantitative analysis, solution design & implementation
•Lead & managed clients’ stakeholders without authority
•Developed & coached internal team members in Lean & consulting skills
•Internal coach for public speaking, implementation skills, advanced excel analytics, lean principles & presenting
Key Achievements:
•Lead 17 projects over 6 industries & governmental with 100% success rate
•Deployed systematic one piece flow on production lines of the Coldstore Group of Saudi Arabia (CGS) improving: 43% lead time, 63% work in progress (WIP), 56% handling & 960 m2 of space
• Remodeled sales vans turnaround for the largest distributor in Saudi Arabia for Mars, Reckitt Benckiser, Americana, Wrigleys & Holisten, reducing salesmen restocking time by 85%
• Developed standard Total Quality Management ready to implement program
• Reduced FTE by 15% & waste by 27% for a multinational FMCG
• Improved Aluminum Foil production facility space by 30% & stock count by 73%
• Deployed a Lean production system for a restaurant chain in Saudi Arabia, resulting in 90% reduction in delivery time
• Implemented Risk Based Maintenance for the bus department of the Roads & Transportation Authorities (RTA) of Dubai
• Designed central distribution center for retail business in enabling 110% of the supply capacity
• Lead the packaging area of the largest Twix® line globally from blueprint to production
• Lead & developed 70 direct reports (production, maintenance & quality engineers & operatives)
• Drove operational Excellence & Center Of Expertise for baking technology
• Emphasized the Lean mindset & the usage of its tools
Key Achievements:
• Won best efficiency project in North Africa & Levant region at the Mars 2015 global awards
• Knowledge transfer from/to Mars units in Germany, The Netherlands, Russia & UAE
• Implemented Operational Method Sheets for the first time within Mars globally
• Developed a global best practice for pre-production preparations
• Lead cross functional plan for Commissioning, Validation & Start-up Management
• Lead a team training at Mars Germany & The Netherlands, fully operating the lines
• Co-lead the installation of the new Chocolate Making facility
• Parallel role, Regional Lean Coach
• Managed & optimized factory capacity, equipment & resources performance
• Handled regional & local Lean projects calendar & KPI’s scorecards
• Lead the Focused/Continuous Improvement Pillar in the TPM & Factory system
• Tutored & Coached in the globally acknowledged “Mars Lean Academy”
• Provided visibility to the markets on line capacities & capabilities for supply activities
• Co-leader of the SKU activities implementation team
Key Achievements:
• Won best sustainability project in Middle east, Turkey & Africa region at Mars 2013 global awards
• Lead the creation of an Idea Generation Program, achieving $1.2 million annual savings
• Provided capacity, equipment, learning curves, IRR, manpower calculations for the Twix® line preparation & project approval
• Lead cross-regional simulation of Twix® line performance & asset portfolio validation
• Co-lead the regional gate cost reduction project
• Programmed a VBA tool to replace the factory performance software
• Designed Minimum Order Quantities automated model
• Co-lead achieving zero to landfill waste (first site outside EU & US), the 2014/Q1 Sustainability Champions for Mars Global Chocolate & 2013 best Sustainability Site
• Executed modifications & optimized the assembly lines based on capacity & design
• Designed & implemented new lines layout & follow-up on the implementation
• Justified the acquisition of capital/expense to optimize the process
• Lead & developed 23 direct reports
Key Achievements:
• Implemented line balancing, Takt time & waste minimization for 6 production lines
• Programmed a software tool handling daily line resources balancing
• Conceptually redesigned the whole layout of Cairo plant for lean
• Lead the transfer of a new production line from the plant in Spain
Started a business with 2 partners for design, manufacturing and assembly of interior modern wooden furniture & kitchen with 2 successful projects.
Preparations Credits
Thesis Grade: A / GPA: B (German system)
Physics & Mathematics focus