Operational Excellence Manager
Saint-Gobain Glass Egypt
Total des années d'expérience :21 years, 9 Mois
Appointed to link all company's functions to apply World Class Manufacturing standards in Operations, with main objective to eradicate and eliminate different types of wastes for better company's profits. Allocate company's different types of resources reaching best fit-mix of people, equipment & methods to fulfill its objectives. Managing 5S & Training programs improving employee’s performance. Enhance employee’s engagement to the company’s objectives of excellence.
Restarted the 7 Years Journey for Industrial Excellence by 1.5% Reduction in Manufacturing Cost, including program foundations, teams, control systems and resources reorganization for sustainable results
Officially certified the plant at 17% compliance to the program in less than 1 year with 1.9% Reduction in Manufacturing Cost
Hired to manage Logistics operations and lead team of 170+ across multiple logistics areas, including production planning, stock and inventory management, logistics maintenance management, HR, transportation-freight-shipping, bulk vessels handling, process improvement, budgeting, and several others. Report to the Plant Manager. Liaise and negotiate with the sales department as well as with suppliers for various logistics initiatives. Create and execute functional budgets.
Manage order cycle, performance/plan improvements, cost and efficiency control, export activities, warehouse/packaging, inventory levels (glass, packing consumables, maintenance spare parts), and maintenance for logistics warehouse, equipment, and tools. Develop business through analyzing logistical problems and create the best solutions. Build the Supply Chain Business Plan, apply WCM and ISO standards, and contribute to strategic, company-wide decisions.
Achieved series of successful certifications with zero non-conformities, including ISO 9001 certification in 2011, OHSAS 18001 certification in 2012, and ISO 14001 certification in 2013.
Implemented structure changes to save 12% of headcount as well as instituting shift pattern changes to transform a 24x5 into a 24x7 operations. Additionally implemented information flow systems that improved dispatching, planning, production, and quality control areas.
Drove multiple cost reductions that included the following: Export Freight Cost Reduction (11%, 2011; 17%, 2012; 11%, 2013), Packing Cost Reduction (34%, 2011; 25%, 2012; 25%, 2013), Equipment Rent Cost Reduction (45%, 2011; 20%, 2012; 10%, 2013), and Finance Validated Cost Reduction + 2 MUSD Applying WCOM®.
Generated quantifiable results across multiple operational areas: Warehouse Storage Space (35%, 2012; 25%, 2013), Inventory Accuracy (to 99.8%, 2012), Production Planning Accuracy (80%, 2011; 91%, 2012; 93%, 2013), and Productivity Improvement (25%, 2011; 27%, 2012; 17%, 2013).
Brought on board to oversee over 6, 000 SKUs of raw material and 2, 500+ SKUs of finished goods, managing over 350 suppliers across the U.S., China, Japan, and Europe. Directed team of 150+ with the Logistics Service Provider Implant Team. Oversaw supply chain comprised of 3 consolidation centers (U.K., Germany, Spain) for raw material and 2 consolidation systems (U.K., Slovakia) for exported finished goods. Ensured top service to primary customers that included Land Rover, Aston Martin, Jaguar, Ford, and other Tier 2 automotive suppliers.
Managed freight budget of 6 million-plus Euros and supervised team of over 25 in inbound/outbound freight tasks. Developed strategies to meet operations, efficiency, and quality goals. Monitored operations to ensure optimal outbound solutions, appropriate level of materials, and proper KanBan system implementation. Prepared and executed project plans.
Achieved 17+% total logistics cost savings in 2009; achieved 11% freight budget savings through smart solution in raw material consolidation process, 21+% packaging budget savings through new packaging types for finished goods, and 23% in warehousing budget savings through outsourced warehousing solution that also cut cycle time 18%.
Increased business unit volume by 12% through implementing new consolidation center for finished goods in Slovakia that attracted Eastern European customers via low logistics cost.
Reallocated resources and redesigned store layout to gain 30% additional space and improve accuracy of received goods; additionally decreased stock levels 30% by controlling WIP and raw material flows.
Drove continuous improvement for transit times and landed costs by leading cross-cultural team of freight forwarders and consolidation centers (German, Spanish, English, Portuguese, Slovakian, Egyptian).
Reviewed existing warehouse procedures and identified opportunities for improvement, including streamlining of production, purchasing, HR, distribution, and other areas to meet product distribution goals. Implemented decisions on inventory movement, storage, and processing. Monitored activities across multiple locations, including Sudan, Egypt, KSA, Bangladesh, and Algeria. Established strategies to reduce costs, improve accuracy, strengthen safety, and enhance customer service.
Decreased area of rented warehouse in Algeria by 40% through implementing changes in resource allocation. Sold obsolete stock of 2 MEGP, optimized existing stock, and created system for efficient inventory monitoring.
Recommended switch in reporting system from Excel to Access, representing significant improvement in information management by shifting from scattered files to a strongly built database.
Progressed through increase in responsibilities. Directed all aspects of refrigerated fleet of 8 reefers work between EGP and KSA from selling, marketing, financial, and production view of management. Supervised team of 50+ and managed fleet of 15+ heavy trucks. Ensured fulfillment of quality control objectives.
Increased the company’s customer network and service levels. Additionally developed web site for the company to receive orders for pick-ups, improving service as a result.
Founded main reporting systems and control systems from the ground up.
World Class Manufacturing Black Belt
Gr. Belt Workplace Management (5S and Autonomous Management) at World Class level in Manufacturing
Recommended as Expert
Recommended as Expert
Recommended as Expert
Recommended as Expert
Recommended as Expert
Recommended as Expert
Excellent Project in SCADA systems and PLC Controls
