Process Engineer and OEE Coordinator
Leoni Wiring Systems
Total years of experience :8 years, 3 Months
• Conduct capacity studies for machines and tools while considering the new projects.
• Create and improve layout for the factory’s areas to optimize process flow and save space.
• Optimize daily plan by restricting material on the machines while maintaining line balance, tools compatibility with machine type and number of available tools.
• Lead OEE improvement projects through a cross functional team.
• Reviewing the plant segment Process Failure and Mode Analysis (P-FMEA).
• Calculate output, performance, availability and OEE target for Egypt.
• Coordinate training of operators with segment leader, shift leaders and training department.
• Applying Total Productive Maintenance pillars over the 5S foundation.
• Following Lean methodology in eliminating 8 wastes and using KANBAN system.
Top achievements
• Leading a large project for OEE and Efficiency improvement with an output of 5% OEE increase and saving of €100, 000.
• Core member in Six Sigma Scrap Value Reduction project saving €300, 000 in 2018.
• KATA Project Mentee to increase plant performance with and output of 11% performance increase and saving €98, 000.
• Reconstructed the factory's layout which resulted in saving 125m2, improved material flow, resource flow and better visual for the factory.
• Contributed in the success of implementing a new manufacturing execution system which acts as a solution for optimization and controlling complex processes.
• Created a comprehensive daily report which is available for all departments to easily and rapidly visualize trends for Output, Availability, Performance, OEE, Breakdowns, Change overs and Scrap value.
• Lead the workshop team and assign daily tasks.
• Create preventive maintenance program for a heavy equipment road recycler (WIRTGEN WR240).
• Create spare parts replenishment plan for the heavy equipment.
• Repair equipment breakdowns and avoid any delays to the project.
• Create training programs for technicians to be able to pilot or perform maintenance tasks.
• Participate in purchasing committees as a technical member.
Top achievements
• Road recycling for 18 km using full depth reclamation equipment for El Dabaa road (AlexandriaMatrouh road).
• Road recycling of 16 km using full depth reclamation equipment for Ras Ghareb-Hurghada road.
• Create daily and weekly production plan for all the production lines and monitor its implementation while solving the problems that could affect it and taking the needed corrective actions.
• Communicate with the supply chain team and collecting the required data for building the plan.
• Report production feedback and availability of material on daily basis.
• Work closely with production team to ensure the updates of production regarding the daily plan.
Top achievements
• Improved the monthly plan building process to meet the required forecast considering the complex bill of material of the units and their available components by designing a number of excel sheets related to data on SAP.
• Implemented a better communication system between factory workshops.
• Eliminated the risk of orders duplication while building the plan.