Manufacturing / New projects Engineer
General Motors
Total years of experience :15 years, 0 Months
• Increased the plant productivity by 45% through introducing new improvement initiatives and implementing them
• Identify and analyze production issues and lead to implement the proposed solutions
• Determine the required machinery and equipment for achieving the required production volumes
• Support the production lines by recommending the proper assembly tools
• Prepare the assembly process sheets and the required documents for the operations
• Develop new project studies for plant enhancement
• Enhance the ergonomic work conditions on the line while adhering to the highest safety standards
• Perform time and motion studies and specify the required headcount
• Manage the Manufacturing Capital Expenditure budget ensuring smooth implementation of the planned projects
o 2014: 12 projects with CAPEX $5.97M & OPEX $0.89M
o 2015: 25 projects with CAPEX $5.86M & OPEX $0.47M
o 2016: 12 projects with CAPEX $19.1M & OPEX $1.63M
• Analyze the current plant status on yearly basis to determine the required project list along with their priorities (MTP)
• Monitor the projects implementation to ensure adherence to the plan and budget
• Lead the manufacturing launch team of the new Chevrolet Passenger Vehicle
• Prepare the launch plan according to GM global launch process and procedure
• Control and track the project budget of $6.9M
• Drive adherence to master timing plan while validating all shops implementation plans
• Lead the tools, machinery & equipment selection, technical tendering and installation
• Design and lead the manufacturing of the required assembly fixtures
• Train the production line operators on the recommended assembly process while considering and improving the safety and the ergonomic level of the line
• Identify error proofing methods for critical operations
• Supervise all contractors tasks ensuring timely adherence to the plan
Project: Reengineering of Asfour Crystal’s Central Workshop.
Target: Converting the central workshop of Asfour Crystal (serving 32, 000 employees) to be a Strategic Business Unit.
• Documented the current work flow with the aid of process maps and data flow diagrams.
• Reengineered the Work Flow and designed the necessary documentation - forms, reports, and checklists.
• Established the Standard Operating Procedures for the different departments of the Strategic Business Unit.
• Monitored the new Work Flow through the developed control points (client care, material control, and financial control).
• Provided support and coaching for the current departments such as Design, Technology, Production, and Warehouse departments.
• Initiated and managed new departments such as Project Management and Outsourcing departments, and developing their work procedures.
• Initiated a barcode follow up system for projects and production.
• Interviewed and employed high caliber professionals to support and maintain the newly applied system.
• Identified the main problems in the work cycle and proposed SMART solutions.
• Completed a full gap analysis for the workforce of the central workshop of Asfour Crystal.
• Restructured existing sections as the Document Control section and created their SOP.
• Designed and developed a project’s archiving system, and a project’s log file for the central workshop of Asfour Crystal.
• Designed and conducted Random Activity Sampling studies for improving the productivity in the production department.
• Upgraded the information technology infrastructure and software of the central workshop of Asfour Crystal.
• Tracked the project progress, and prepared the necessary reports for the project manager.
• Supervised the installation, commissioning and the start up of a new PET line for juice filling.
• Leaded to implement the production plan while maintaining high efficiency and continuous production.
• Maintained high level of hygiene and organization in the production hall.
• Trained the new hired production engineers and operators of the PET and the Combibloc lines.
• Implemented more than 16 New Packaging Development projects for the AIME region.
• Finalized the packaging technical specifications for the Dubai Factory.
• Designed, implemented, and monitored the R&D Lab in Dubai.
Awards: • Awarded by the school of Sciences and Engineering a certificate of academic honor in the Dean’s honors assembly, Spring 2007, Spring 2008. • Dean's list of honors, AUC, Fall 2004, Spring 2005, Fall 2005, Spring 2006, Fall 2006, Spring 2007, Spring 2008. • Awarded the most responsible member of the Student Union Academic Committee, Spring 2006. • Awarded the most active committee for the Infrastructure project, Help Club, Spring 2006.