Material Handling Area Manager
General Motors Egypt
Total years of experience :17 years, 6 Months
Lead and manage the material handling team to play their key role in:
• Set section’s yearly business plan in Safety, People, Quality, Responsiveness, Cost & Environment & set internal targets to match departmental objectives & goals
• Ensure the use of proper tools & assign right resources to achieve business plan targets
• Prepare annual section CAPEX, study & submit business cases for approval
• Conduct packing design & improvement & vanning layout for current & new models. Conduct bi-weekly meetings with source plants for packing initiatives & waste elimination
• Manage inbound & outbound delivery for overseas parts. Create service providers scope of work, monitor & assess their performance & provide monthly KPIs
• Set priorities & level trucker & receiving activities for best use of resources, & assign weekly storage plan based on receiving & production plan. Coordinate with customs, logistics & trucker to expedite or delay shipments according to production plan, demurrage & space availability
• Ensure material segregation & report non-conformity & obsolete. Participate in rejection, obsolete, insurance committees
• Regular update of Plan for Every Part for all productive material.
• Material Warehouses layout design & update for lean storage, un-boxing & delivery process
• Design replenishment Strategy set unboxing & delivery process cycle
• Provide safe & healthy working environment through safety & ergonomics audits, set action plans & make sure action is place & effective
• Set staff & operators training plan, conduct regular communication meetings, set yearly & monthly targets & conduct mid & end year appraisals
• GMS SME for Short Lead Time principle for manufacturing & supply chain departments
• Accomplishments
o Managed Plant facelift phase 1 project (migration of rear floor assembly station, new fuel station, new docking station with hydraulic levelers) within 8 Mil EGP budget
o SPS delivery methods implementation in passenger line achieving 20% target penetration & improving direct run (quality) by 2%
o Flawless launch of Captiva facelift with deliverables within targets & according to plan
o Improve packing with source plants & achieved 0.5 Mil EGP annual saving through returnable containers projects
o Reduce line rejection through repackaging project leading to 30% reduction in plant fault
o Overseas assignment for packing improvement workshop & SLT audit in SGMW - China source plant
Member of SAP Project System implementation team for MM & PP Modules in General Motors Egypt. Represent manufacturing department in system building phase & provide support after go-live
• Study technical requirements & present business case for approval
• Assess & submit manufacturing department business cycles
• Review & modify offered business cycles to match GM requirements
• Complete system user acceptance testing in 5 weeks workshop in Data Flow South Africa. Review all business requirements within the system & set action plan to close all issues & defects
• Map authorization by role, storage location & movements for manufacturing department users & test
• Train manufacturing department on SAP application in different business process
• Lead the manufacturing department in the Organization Change Management program
Body Shop Process Supervisor, General Motors Egypt, January 2011 - January 2012.
Lead and manage the body shop process engineering team to play their key role in: • Providing technical support to the Production, Quality, GPSC, Marketing and Sales Teams.
• Ensure the use of proper tools to achieve the business plan targets in Safety, People, Quality, Resposivness, Cost & Environment; this involves the consideration of ergonomic assessment, Global Design for Health & Safety, Built in Quality & Productivity in production facilities & assembly tools identification, generation of plant layout and process flow of assembly operations, parts evaluation, manage process materials, & solving quality problems.
• Manage & lead new projects from manufacturing side from business case to start of production in a cross-functional environment.
Senior General Assembly Process Engineer, General Motors Egypt, March 2008 - January 2011.
• Setting up sequence of operation for current & new models, issue material distribution list and determine process material.
• Identify production problems, analyze & propose solutions and develop ideas for improvement.
• Determine fixtures, tooling, handling carriers & prepare documents necessary for operations.
• Develop & estimate required investment for new projects.
• Adhere to ergonomic factors and safety rules in operating conditions.
• Perform time & motion study & determine headcount
• Leadership positions & accomplishments
o New Captiva Launch (Trim line), January 2009 - October 2009
o New Truck 700P Program, June 2009 - August 2010
o Truck Line Conveyor, August 2009 - May 2010
o Chevrolet Lanos Launch, May 2008 - October 2008.
Responsibilities: Preparation & presentation of project investment. Tools, machinery & equipment selection, technical tendering & installation supervision. Operation distribution & sequencing. Assembly fixtures design. Train operators on assembly. Improve safety & ergonomic level of the line. Error proofing for critical operations. Increase line capacity & improve HPV.
Industrial Methods Engineer, Schneider Electric Egypt, July 2007 - Mach 2008.
• Implementation of lean concepts in manufacturing process & updating manufacturing times.
• Mapping the value stream of a product family at the process level.
• Working on material providing and handling from warehouse or suppliers to workshop.
• Write down instructions for every workstation covering manufacturing, quality & safety issues.
• Adhere to ergonomics a safety rules in operating conditions.
• Assure continuous improvement.
• Leadership positions & accomplishments
o Low Voltage Line Material Providing & Handling System Improvement, September 2007 - February 2008.
* Responsibilities: Assessment of line & warehouse needs, design material racking, simulate delivery interval & quantity, implementation & buy-off.
o Low Voltage Cells Value Stream Mapping, December 2007.
* Responsibilities: Create the VSM team, distribute tasks to all team members, map the value stream, make the analysis with the team, & finally conclude the main area for improvement & assign roles.
Consulting Engineer, Allied Training & Consulting, Aug 2005 - Apr 2006.
• Introducing Job Shop scheduling technique and explaining how to use scheduling software packages in the HI-Tek Company as a part of designing production planning and control procedure for the Company, March 2006 - Apr 2006.
• Opportunities for Development and Improvement of the Mit Ghamr Aluminum Cluster; which consist of: Aluminum industry profile, Technology assessment of secondary aluminum production at Mit Ghamr, Procedure analysis, Risk analysis aluminum production at Mit Ghamr, Proposed technological improvements, Suggested investment opportunities, Jan 2006 - March 2006.
• Coordinate the project of Experts Designation and documentation of maintenance system for moulds and dies with theoretical and practical trainings as well as implementation courses. This project was intended for five beneficiary companies in 6 October city, Aug 2005 - Jan 2006.
Certified in Production & Inventory Management
• Bachelor of Science, Mechanical Engineering, Mechanical Design and Production Section, Ain Shams University, Egypt, July 2004 - Grade: Very Good.
• Egyptian High School Certificate "Thanaweya Amma", Science Section, Lycée La Libertée School, Egypt, July 1999 - Scored 95.8%.
