Manufacturing & Supply Chain Director
Easy group
Total years of experience :19 years, 5 Months
Leading the E2E Supply Chain from demand planning to product supply, import, and clearance up to warehouse management, delivery of goods, and supplier selection process.
Leading the manufacturing operations in 2 factories & the R&D function.
Leading the project of establishing a new business unit is KSA including building 2 factories and their SC.
Conducting the feasibility study for KSA project and designing the conversion cost model for all products.
Leading the SC & factories due diligence process during Fine Hygienic acquisition over Easy Group.
Responsibility for launching a new factory project during the design and feasibility study phases.
Leading 8 operation departments (safety, QC, QA, CI, processing, sterilization, maintenance, warehouses) in a B2B food factory.
Responsibility for achieving & obtaining sustainable long-term improvement in EBITDA and Free Cash Flow.
Achievements:
Improving plant OEE by 7%.
Improving sales plan weekly adherence by 15%.
Formulating and launching a new KPIs scorecard for white collars & blue collars.
1. Manage manufacturing performance (OR%, OEE%, Savings, etc.) for 7 production lines. Managing a team of 260 supervisors, operators and packers.
2. Reduce safety TRFR and customer complaints. Implement quality maintenance tools.
3. Conduct gap analysis for OEE, production cost, material waste, labor productivity, and other KPIs.
4. Lead Focused Improvement pillar (eliminate top quality defects, safety risks, and cost losses).
5. Lead Autonomous Maintenance pillar. Formulate and implement operators training program.
6. Manage department spending (OPEX & CAPEX).
7. Plan and execute new innovations in coordination with other concerned departments.
8. Participate in the factory digital transformation strategy and project initiation and execution.
Achievements:
1. Decreasing the production lines manning by 10% through NVAA improvement.
2. Leading RM&PM wastage reduction project that resulted 54% decrease (12 Million EGP saving in 2017).
3. Achieving and sustaining 95% weekly production plan adherence.
4. Zero safety & quality incidents during 2017.
1. Plans and directs production activities of 15 production lines through effectively leading a team of 2 shift managers, 5 production engineers and almost 700 supervisors, operators and packers.
2. Coordinates production activities with supply chain, engineering, QC, EHS, and QA to obtain optimum production and utilization of human resources, machines, and equipment.
3. Control department spending (OPEX & CAPEX).
Achievements:
1. Decreasing the production lines manning by 5% while having the same output.
2. Increasing the production lines efficiency by average of 20%.
3. Initiating and implementing new Job Order system for production lines.
4. Initiating process optimization projects (reducing MUV, reducing scrap %)
5. Participate in initiating new KPIs scorecard for the plant.
1. Manage the executing of the yearly S&OP through directing 5 production lines and a team of 3 engineers, 6 foremen, 48 machine technicians, and 175 packaging workers.
2. Drive continuously the improvements in plant productivity, cost of non-conformance, downtime reduction, and wastage of raw and packaging material.
3. Ensure safety and quality standards are met by complying with ISO-22000 & OHSAS-18001 standards.
4. Oversee the recruitment, training, discipline, and performance reviews the production team.
5. Formulate and lead the implementation of TPM programs in the plant.
6. Prepare production department Budget and CAPEX.
7. Liaising with other departments for the new products launch projects.
Achievements:
1. Improve the 5S assessment score of the shop floor from 29% to 86%.
2. Increase the production output by 20% without extra manpower or equipments.
3. Decrease the plant startup time by 75% by implementing the SMED methodology.
4. Improving the technical skills of the machine technicians from 74.4% to 94.3% through (AM).
5. Increasing the production lines OEE from 78.5% to 83.4%.
6. Increasing the multi-skilled workers percentage in the plant during 2014 from 22% to 73 %.
7. Increase the productivity of the packing workers by 75%.
8. Leading 3 interim projects ( 2 lean projects + 1 ergonomics project)
1. Managing a team of 2 engineers, 4 foremen, and 200 workers. \n2. Direct, analyze, and develop production activities to meet established targets in terms of production specifications, schedules, volume, cost, wastage, and quality. \n3. Analyze production, maintenance, and malfunction records to identify problems and recommend solutions. \n4. Lead, develop, train and hire the team of engineers who are responsible for the various production activities. \n5. Lead the implementation of a Lean Manufacturing project within the plant.
1. Managing a team of 10 foremen, and 200 workers.
2. Execute the weekly production and assembly plan depending on the S&OP forecast.
3. Ensure meeting high quality standards throughout the production line.
4. Promote and maintain a safe work environment by complying with OSHA standards.
5. Work closely with sales, marketing, engineering and quality assurance departments for new product development and launching.
6. Create and develop the culture of Lean Manufacturing.
I was working as a production shift supervisor for Cargill which produces soybean oil and meal. I joined the company at 1/ 7/ 2004 as a production engineer. I was promoted to a shift supervisor since October 2006.
Responsibilities:
1. Managing the operations of the plant during the 12 hours shift, through a team of 5 engineers, 5 technicians, 1 mechanic, 1 electrician, packing & cleaning contractors, and 4 logistics employees.
2. Manage the execution of the Production Plan through analyzing and resolving production problems.
3. Implement process improvement projects to enhance productivity and energy efficiency.
4. Manage the product quality. Participate in implementing the HACCP program.
5. Develop the safety awareness, risk management permits, and incident investigation.
6. Participate with the maintenance team to establish a planned maintenance schedules.
7. Establish team development plans, on-the-job training, job rotation, and staff evaluation.
Achievements:
1. One million EGP increase in yearly revenue through a six sigma project.
2. Participate with the HACCP team to get the HACCP certification for the plant.
3. Develop and lead the implementation of the Behavior Based on Safety (BBS) program that was applied as the regional best practice.
4. Establish and apply a visual performance management system.
5. Passing the global automation audit certification with the cooperation of the automation team.
6. Commissioning, starting up, and training the local team at Cargill new rape seed plant in FRANCE.
Mechanical Power engineering department.