Operation director
Saint Gobain
مجموع سنوات الخبرة :19 years, 7 أشهر
Leading the operation for three gypsum plants and two gypsum rock quarries to produce traditional and value add plasters in addition to EHS and product development department (365 employees).
Implemented World Class Manufacturing (WCM) program attaining industrial efficiency saving of 1 % of manufacturing cost in 2018, 1.5% in 2019 and 2% in 2020, through continuous improvement projects for waste reduction, increasing productivity and energy optimization
Innovated new value added products resulted in increasing topline by 20%
Reduced head count by 27% through change management and organization development
Delivered successfully capability upgrade project to produce mixed plaster with budget 6 M Euro
Awarded for joining Saint-Gobain millionaire club (Environment health & Safety Global awards) as result of attaining more than million working hours without LTI or NLTI in all sites
Attained waste reduction by 10% by lean manufacturing through recycling system, 5S model, reduced products change over and process improvement
Integrated customer service and quality improvement program resulted in reducing the customer claims by 77% in 2018, 45% in 2019 and 36% in 2020
Streamlined warehouse management program with improved inventory control and material planning that result in reducing working capital by 7 days
Increased plant reliability by 10% reaching 95 % by improved preventive maintenance, spares management and implemented kaizen activities
Delivered new projects with Capex budget of 10 M Euro in two cement plants as per project management standard
Implemented projects for new warehouse and palletizer (2.5 M Euro), drying system (3 M Euro) and new steel silo for road cement (1.5 M Euro)
Reduced spare parts stock by 22.6 % through inventory management by calculated safety stock and EOQ using Maximo
Conducted logistics project with supply chain team reduced the dispatch cycle time by 22 %
Managed the commissioning of new cement line (Cement line Budget 320 M Euro)
Led the performance improvement of the cement grinding area and packing through change management, people development, team building and improved maintenance by leading operation team with head count of 285
Exceeded the operation budget production volume by 8%, variable cost reduction through waste reduction and energy optimization resulted in reduced cost per ton by 9%
Attained 6% improvement in reliability and 5% increase in productivity versus budget
Executed the commissioning of new power plant supplying two cement plants with capacity of 102 MW - 6 Engines of 17 MW each and project budget of 70 M Euro (80 employees)
Optimized the operation performance resulted in the lowest unit power cost and achieved power availability 99.9% and reliability 99.5%
Created and implemented energy isolation system in the cement plant and power plant
Lafarge - a manufacturer of building materials (primarily cement, aggregates and concrete)
Project engineer CIBA cement Plant (Algeria - Oran). \[September 2007 - April 2010\]
(New cement plant with project budget: 900 M Euro): During commissioning of CIBA cement plant with grey cement line of capacity 6000 tons/day and white cement line of capacity 1000 tons/day Led the commissioning activities between the operation team and the contractor team (FLSmidth). Conducted the feasibility and design studies for the industrial projects and supervised the execution on site during the normal operation period for the grey and white cement line.
Safety compliance according to Lafarge safety rules.
Delivered the right products that met the company’s quality standard and contract requirements.
Led project teams and facilitate the communication and interaction among the functional representatives through planning and execution phase.
Tracking the project against its schedule, budget and against phase review objectives and generate cost and progress reports.
Led the contracts negotiations.
Project Engineer Achievement
Succeeded in leading the commissioning for the cement mills shop (2 X 200 tons - ball mills - closed circuit) and packing plant during the commissioning of the grey cement after the transfer of the site manager to another location.
Lafarge-Titan Egypt - a manufacturer of building materials (primarily cement, aggregates and concrete).
Mechanical Planner - Alexandria Portland Cement Plant - Egypt. \[November 2006 -August 2007\]
Safety compliance according to Lafarge safety rules.
Champion of the advanced downtime analysis program (ADAP).
Performed root-cause analysis (RCA) for the major problems in the plant sections (raw mills, kiln, cement mills and packing) according to the Pareto charts analysis.
Re-codification of all the plant equipment according to the standard codification of Lafarge.
Screened the work requests and performed the necessary planning by issuing work orders.
Led spare parts planning and control and purchase requests issuance for required spares or service.
Member for the implementation of the Maximo software project (computerized maintenance management system).
Pepsi Cola Egypt (multinational food, snack and beverage corporation)
Production Line Manager - Amreya Plant - Egypt. \[January 2005 - October 2006\]
Attained safety compliance to safety standard for all the production tasks.
Set up working systems which minimize loss of packaging materials during the production process.
Led the development of all production staff as per the planned development programs.
Developed the master production schedule to obtain desired service levels and plant efficiency.
Ensured timely flow of in-coming and out-going materials required to achieve the local production plan and the local shipment orders to other plants, through planning production needs in line with production requirements and through directing/controlling inventory levels.
Achieved Improvement for the performance of the production lines by building action plans after analyzing the performance measures of the production department using result analysis tool (R.A.T) according to the manufacturing and warehouses program (M & W).
Production Line Manager Achievements
Increased line productivity by 22 %.
Reduced production packaging loss by 28 %.
Increased Line 2 Net efficiency by 7 %.
Production Engineering Department, Faculty of Engineering, Alexandria University. (Part time during the period for applying to the military service) - \[October 2004 to November 2004\] as Teacher assistant: Teaching the Technical Report Writing using MS Word and MS PowerPoint according to the ANSI standard.
Pact Bond Company (Ragab group) Alexandria, (Part time during the period for applying to the military service). \[August 2004 - October 2004\] as Consultant assistant: with Prof. Dr.-Eng. Mohammad Al-Makky, Professor of manufacturing Engineering, Alexandria university (part time). Reducing the manufacturing time through the simulation of the manufacturing process wood cutting workshop.
B.Sc. Project: Discrete Event Systems Modeling and Analysis [Excellent]. •Constructing models using different scenarios to improve the system performance and decrease the cost.
Thanwia Amma