Industrial Engineering (IE) Manager
Mars Saudi Arabia
مجموع سنوات الخبرة :19 years, 8 أشهر
Lead Saudi Plant Capital Projects & New Product Initiatives from planning to successful execution. Facilitate cross functional collaboration to effectively coordinate operational resources required to startup & successfully execute projects (Handling the capital projects of $30 million).
Co-piloting Plant Manager to support S&OP strategy along with supply chain to ensure delivery to Saudi and Gulf Markets. Assessment of capacity vs. demand volumes and recommendation, execution and implementation of projects to considering future growth opportunities. Developing, setting and implementing factory OGSM as part of factory management team.
Evaluate projects in alignment with the regional, site and market strategy to maximize profitability and growth for Mars Saudi, submit business proposal for approval and follow-up with post completion reports. Develop production & distribution layouts, determine manpower requirements, conduct capacity analysis and cost justification. Initiate, conduct, and co-ordinate studies and analysis to identify capacity constraints, bottle-necks and opportunities.
Setting, Implementing and Benchmarking Site KPIs according to Mars global standards. Undertake business process analysis, statistical analysis for improvement projects and to support wider change. Develop specific goals and plans to prioritize, organize and accomplish work with continuous improvement mindset.
Notable Achievements
• Successfully delivered Chocolate Crumb manufacturing facility in Saudi plant with a budget of $22M as part of Supply network strategy for MEA with a capacity of 40K tons per annum
• Delivered 23 New products initiatives for Saudi and Gulf Markets generating earnings of $17.7M within the projects time frame
• Delivered Capacity Enchantment projects on Chocolate manufacturing lines to achieve 24% additional volumes (i.e. from base 9.1ktons to 11.25ktons annually)
• Enhanced factory utilization 37% through strong business case and justification that resulted swinging volumes from other regions to Saudi factory avoiding $1.5M duty yearly
• Delivered Value leadership in Production Conversion Cost (PCC/ton) through Scale and Efficiency 7% YOY
• Delivered continuously Best in Class (BIC) Site Performance KPIs in Efficiency (Reliability > 85%), Service (Case Fill > 98.5%), Cost (PCC/ton reduced by 19%) and overall Inter cost of Production (ICP/ton reduced by 30%)
• Deploying Manufacturing Excellence by developing maintenance schedules for equipment. Developing FMEA for processes & Lines. Perform root cause analysis and resolve problems using lean methodologies
Leading technical leadership for designing & implementing processes and production lines as per Mars Global Best Practice (GBP) Standards to ensure manufacturing excellence. Responsible for commissioning, validating & starting up new Manufacturing facilities, Lines, Products till handover to deliver market requirements while ensuring Product quality & food safety legal compliance. Assist with all mechanical aspect related to equipment selection, design, installation, commissioning and startup planning.
Developing, testing and evaluating theoretical designs (Blue Prints) with the Mars Global technology leaders for developing new Molding line and Liquid chocolate manufacturing. Determining Technical specifications of projects by understanding process & product specifications, drawings & P&ID, customer requirements & completing technical studies. Deploy 6 sigma methodology to improve the quality of the output of a process by identifying and removing the causes of defects and minimizing variability in manufacturing and business processes.
Notable Achievements
• Successfully Commissioned Green field project of Mars Saudi Arabia for Chocolate Production Process & Molding Line ($60M Project - New Facility)
• Successfully commissioned the new M&M’s packing tubes line with highest line speed in all Mars Sites of 400 tubes/min ($17M New Line)
• Successfully Commissioned 12 new Products in Molding Line & delivered 6 recipe changes
• Green Belt Project on weight control on molding lines to deliver 314K USD in 3 years
• Green Belt Project to Reduced NQC (Non-Quality Cost) by controlling Material usage variances vs. BOMS from 4.2% to 2.2%
• Delivered 20% Saving on Raw & Packaging Material Savings through COGS projects delivering $3.2M savings
Provided leadership and management to Packing Module Production Operations and ensured the organization effectiveness of the team in line with customer demand and service level, minimized costs where possible and ensured the required best working practices were maintained. Led the strategic direction of the manufacturing operation in the context of an ever-changing environment, included championing the implementation of WCM
Boosted delivery and scheduling efficiency by ensuring Key Performance Indictors (KPIs) of Production lines & Analyzing results by gap analysis. Delivered annual production volumes for Bar Soap Packing Line, PUR Sachet production lines and Pampers repacking operations with optimization of department budget & collaboration with cross functional teams.
Ensured that the Packing Module Manufacturing operated in accordance with health, safety and environmental policies and procedures and assisted staff by recruiting, training and developing personal growth opportunities.
Notable Achievements
• As “Startup Leader” delivered Vertical startup with 80% reliability of new 2nd packing line for Soaps as up
• As Department Manager, managed to meet production targets for the years 2008-2011 with 82% Reliability
• Delivered Production KPIs for Safety, Quality, Efficiency and delivery all in green scorecard
• Delivered Autonomous Maintenance Leadership Model for P&G Hub Site @ AM Step 3 & implemented the roadmap of AM pillar for the site with more than 99.5% adherence.
• Managed to deliver savings of $1.6M savings on Production budget by loss elimination and VSM. And further optimized maintenance plans for equipment, machines, spares management, operating supplies, wages & overtime
Led and was responsible for Planning, controlling and evaluating the operations of bar soap lines production & delivering daily, quarterly & annual KPI’s i.e. Machine Efficiency, Quality, Safety & Cost. Driving Operation Efficiencies by developing, scheduling & Executing maintenance plans for equipment.
Developed Standard Operating Procedures production line to address all Production/Manufacturing quality assurance requirements as per company standards
Conducted Technical Training of technicians on machines and equipment
Ensured the Site Reliability targets for Machines & Lines by applying Reliability Engineering (RE) tools identifying and managing asset reliability risks that could adversely affect plant or business operations.
Notable Achievements
• Delivered 11% increase in Soap Wrapping machine efficiency
• Delivered 18% Savings on Raw & Packaging Material with Quality support ($1.3M)
• Delivered project of Proficy LEDS (Line Event Data System) for soap packing lines to ensure all the unplanned Reliability losses could be minimized through accurate data analysis
• As “RE Owner”, managed to increase the Process Reliability by 5% YTD for FY 09~10 that resulted $ 1.1M savings to the company
• Maintained PQM > 500 PPM’s YTD
Led Frame Assembly Production team to meet Production Targets for Day to Day, Quarterly & Fiscal Year for motorcycles. Ensured and delivered the production KPIs of manufacturing line as per the company targets.
Ensured Managerial responsibilities in staffing, training teams, driving efficiency and assessment of all reporting employees
Notable Achievements
• As startup leader, delivered 500K Synchronized Frame Assembly Line project as a part of capacity enhancement plan to produce 500, 000 Motorbikes