foundry expert
عمل حر
Total years of experience :21 years, 6 Months
Diagnose and fix technical and or managerial problems upon agreement with certain company.
Improve material usage and classify products as customer characteristics.
Make a quality control check on products in several locations
Improve material usage and classify products as customer characteristics.
Make a quality control check on products in several locations
• Sheet metal working, welding 1G & 2G rolling sheets and manufacturing tanks dishes as to UL standard.
• Special paints for long life products and testing thickness and paint homogeneity.
• GRP (grain reinforced polymer) coating for tanks as customer request
• Welding lines and joints testing.
• Testing paint material and coating.
• Testing GRP coat on fuel tanks
• Working as an operation manger coaching the following departments (production, quality, quality assurance, planning, drawing technical office
• Making a perfect data bath from sales to production and quality in fuel stations tanks
• Working on all quality problems, rejection rate, low yield, surface quality. After and before machining.
• Make an action plan for the rejection of products after machining. Also executing the action plan and lead the team of quality to control.
• Gathering the problems of assembly either defected parts or lake of parts.
• Also the actions from the assembly on the foundry.
• At the last position I was responsible for the molding machines, productivity, manpower as a foundry manger
• Work on all quality control issues in the foundry, machining shop and the assembly shop.
• Follow up daily scrap, establish controls, and follow up application.
• Receive customer complains and lead teams to deploy the problems.
• Review and continual improving of the control plan and all quality documentation.
• Apply quality system for GM Egypt to meet there requirement of N 300 van.
• Working as a production responsible in Amerya Metal Company in Alexandria
• Then promoted to a quality manger of foundry, machining shop and assembly shop.
• I used to work with five engineers to decrease the rejection rate in the foundry and meet the QSB (quality system basics) of general motors’ GM in the assembly and machining.
• In November 2012 I was promoted to be production manger of the foundry, as a direct responsibility for foundry, fettling shop, and core shop
• The factory has local and international customers. Also there were automotive local customers.
• Report the missed parts to supplier
• for all foundry tools, tool status, tool replacement, and machinery.
• Responsible Responsible for rejection and cost reduction in consumed materials.
• Improving labor performance and knowledge.
• Solving technical problems in brass melt and core making.
• Raising labor productivity (first bath yield).
• Developing new products.
• Foundry capacity increase study, money authorization and capacity planning
Designing and implementation of the machinery for molds making and manual ramming.
Designing and implementation of the metal transportation and handling, metal testing…etc
Working on all quality problems, rejection rate, low yield, surface quality. After and before machining
• I was responsible for achieving level of quality control in the whole factory in order to decrease the quality cost
• Sourcing all raw material and make all the purchainsing steps untile the finance
• Improving metallurgy projects in ductile and gray cast iron with several targets, Ex. Yield improvement, shrinkage porosity improvement, process improvement, reduction material consumption…etc.
• Improving raw materials quality with suppliers. Projects with S&B industrial minerals France and Germany plants, projects of new materials development with ELKEM ASA Norway. Projects in thermal analysis measurement with CMRDI (central metallurgical research and development institute) in Egypt with Dr. Adel Nofal and HERAEUS Eclctro-Nite intl. NV Belgium.
• Dealing with customers as contact person and attending business meetings with customer (Continental Teves Germany, Triplex England) and the final customers (Mercedes, Volex Wagen, Opal, General Motors, Honda and Ford).
• Using control plan, FMEA, statistical tools, 8D techniques and action plans.
• Issue control, update and follow up all the system documentation policy, quality manual, procedures, forms
• Assuring that the accepted parts are according to the customer requirements and specifications.
• Preparing the feasibility study for the new products and applying the 1st off trials and samples.
• Assuring the process stability using statistical aids.
• Responsible for the ISO 17025 for laboratories accreditation as a project manager.
• Appling corrective/preventive actions and following of action plans in all over the foundry.
• Leading a team of 60 technicians and supervisor. Responsible for the whole headcount evaluation and salary increase for successive three years.
• Plan and coordinate the internal and external training for all employees.
• Dealing with other departments for cost saving and process improvement projects.
• Investigate and report on customer complains.
• Enhance the systems after management approval.
Working in the assembly process of several types of automotive air conditions. More than 20 different part numbers for 13 dealers in Egypt. Also an Italian dealer for exchanger core.