Factory Manager
Kerry
Total years of experience :29 years, 7 Months
Responsible for the overall efficient and profitable operations of the site, while providing site leadership guidance to a diverse employee population, and ensuring company policies are complied with.
Application of Local Knowledge & Experience: Played a pivotal role in aiding Kerry to seamlessly and efficiently develop and expand Manufacturing Footprint in Saudi Arabia - Advised on impact of local customs/ practices/ legislation etc. to ensure that pitfalls that may retard growth ambitions are avoided - Provided local knowledge support to other functions in Kerry particularly HR, Procurement & SC.
Manufacturing Excellence: Ensured that manufacturing capability is suitably configured to optimize and respond to profitable market demand in relation to cost efficiency, agility, speed to market and superior service (OTIF) - Ensured plant reliability index targets are met - Led a pathway towards manufacturing excellence by develop a culture of sustainable continuous improvement. Champion the execution of Kerry's Ways of Working - Optimized existing systems in line with site manufacturing practice while maintaining costs - Led food safety, quality and placed a strong emphasis on the importance of QHSE standards. Ensured the necessary guidance / training is provided to the employees. Project Management: Evaluated project feasibility for Kerry - Proposed and executed Kerry Accelerate productivity opportunities - Assessed capital expenditure and proposed profitable development projects.
Built a High Performing Team (HPT) across the site and other stakeholder groups that focus on common goals and priorities rather than individual or functional excellence.
KPI and Scorecard: Raised the bar on plant objectives and targets Focuses on efforts to keep plant costs low and meet targets - Maintained efficient inventory management system and control - Met volume requirement as per demand, and ensured all third party contractors & warehouse facilities meet and maintain Kerry standards.
Coordinated with the Boards of Directors in designing and implementing strategies, reengineering core business processes aimed at enhancing commercial performance, operational efficiency and service quality.
Prepared and ensured compliance to departmental budgets and assessed long-term financial performance of the company for maintaining organizational P&L including CAPEX.
Leading all commercial and operational plans aligned to organizational strategic directives as well as company leadership Code of Conduct in collaboration with the Board of Directors.
Maintained updated knowledge of statutory regulations/amendments for aligning with organizational policies and procedures in accordance with Total Quality Management, TPM, HSE, & GMP.
Provide strategic leadership to Nada's operational departments: Herd, Fresh Dairy & Juice Plant, UHT Dairy & Juice Plant, Quality Control, Supply Chain, Crops & Horticulture, Projects & Plant Maintenance, General Maintenance, Fleet & MEM Workshop and support services.
Develop and design operational strategies, business process re-engineering and innovation, talent development and retention, environmental stewardship.
Support the company in managing & overseeing the long-term financial performance of the operations through close & effective management.
Establish performance measurement metrics to achieve profitability for the planned growth and expansion.
Establish performance measurement metrics to achieve profitability for the planned growth and expansion.
Drive activities to maintain flat costs, while improving plant performance in the areas of True Efficiency, Safety, Quality, Projects Management and Supply Chain Capability, ensures compliance Quality objectives are met and maintains positive employee relations while driving significant change.
Identify and coordinate improvements in the operations area necessary to meet the variance commitments for the plant and flat cost targets. Ensure that costs gaps are identified, action plans are developed and adequate resources are allocated to meet all financial objectives.
Drive overall Supply Chain capabilities by managing plant wide implementation of TPM, True Efficiency and team development with specific emphasis on the AM and PM pillars.
Achieve all Productivity, Quality, Cost, Delivery, Safety & Motivation KPI objectives.
Provide a work environment which adheres to compliance/regulatory guidelines, ensuring performance against objectives.
Fosters an environment of continuous improvement that meets or exceeds division expectations.
Establish clear performance and behavioral expectations for all employees, provide feedback on results.
Maintain an effective performance management process reviewing all direct report's progress against mid-year and annual plans and continually develop their effectiveness as leaders and technical practitioners, as well as providing opportunity for career development.
Production and Maintenance skills will be heavily relied on to improve plant performance and TPM initiatives.
Systematically lead the identification and elimination of losses resulting in improvements in costs, inventory, time and quality.
Provide active and positive leadership in the effort to drive the cultural across the facility.
Develop and execute the yearly materials requirement planning, staffing, product sourcing, warehousing needs to meet the AOP objectives.
Sets warehousing/procurement performance standards and aligns organization.
Ensure continuous compliance to policies & procedures.
Leads problem solving activities for warehousing/procurement operation; coaches on process improvement.
Create and execute customer driven contacts with key suppliers:
- Obtain lowest total systems cost.
- Agree service level parameters (delivery, payment, …)
- Continuously update COGS, volume forecasts (input to MRP’s)
Continuously monitor supplier performance and develop with supplier’s initiatives to further reduce costs and improve PCI competitive advantage:
- Supplier performance tracking (e.g. % goods on time, quality)
- New initiatives (e.g. packaging developments)
- Compare supplier costs with industry cost/price benchmarks.
- Industry developments (technology, capacity, new suppliers).
- Support the MU’s in problem identification and resolution.
Develop staffing and skill building plans for the warehousing/logistics operation that directly links to AOP objectives. Work closely with HR for effective implementation.
Develop plans with Marketing Equipment Manager in coaching and developing field and workshop teams to fully meet MEM work processes requirements.
Prepare and execute departmental budget for manpower, spares, consumables and fleet major overhauls.
Influence Setting garage workshops performance standards and align organization.
Institute an effective fleet maintenance program to ensure safe and reliable operation.
Stay current on all Department of Transportation Laws and Regulations and ensure the Company fleet of vehicles is in compliance.
Setting the operations organization strategy to insure timely and successful implementation of Company strategy and AOP and Lead the manufacturing operation to safely deliver product in specs and within cost targets to sales.
Ensure plant assets are maintained to meet supply chain demand.
Ensure compliance to all local government regulatory requirements and PI standards considering the organization’s market position opportunities, capabilities and competitive threats and providing functional expertise to the West Africa Markets.
Provide focus and support improvement of cost and product/package quality performance.
Provide support for the execution of BU based materials procurement activities.
Provide support to MUs on implementation, stabilization and sustaining of Best Practice Tools.
Provide ongoing problem solving support to MU to help the MU sustain and improve Best Practice tools results.
Track Best Practice results and give feedback to Worldwide Initiative Owner.
Develop and execute the yearly manufacturing plan (AOP) to deliver the business objectives (production volume, manufacturing controlled cost, quality, safety…)
Lead long-term (3 - 5 years) infrastructure Planning Process (capacity addition, facility expansion…) consistent with the company strategic requirements.
Establish and maintain a standard of performance for the operation. Strive for World Class results.
Establish individual accountability using coaching & support and performance management process.
Ensure product availability in the plants Warehouses per production plan & ready to transport to Satellites & Market.
Establish facility sense of urgency to get things done.
Comply with company's environmental policies and procedures, and contributing to the enhancement of the company's environmental performance.
Implement all control measures and track critical control points to eliminate any possible risks.
Benchmarks performance improvement practices.
Collaborate to plan engagement objectives and a strategy that addresses risk and performance improvement.
Develop productivity standards and manage data collection / reporting; provide updates as needed on key projects, as well as daily, weekly, monthly performance results.
Partners with departments heads to establish performance improvement interventions that meet business needs.
Participate in departmental and other meetings when required, and work in committees, steering groups, etc.
Demonstrate high levels of technical and professional knowledge and quickly assimilate new knowledge.
Participate in capital planning and process improvement project management as directed.
Participate in budgeting process by analyzing data and anticipating future performance improvement.
Develop plans to achieve deliverable within expected time-frame and on budget.
Monitor progress, manage risk and ensure top management are kept informed about progress and expected outcomes.
Commit to developing knowledge, continue to learn and share knowledge with team members.
Lead the development of all managers’ capability to achieve sustainable business results through their people.
Employee policies for the Market Unit regionalized.
On-time and accurate personnel administration to meet employee needs, PepsiCo requirements and legal compliance in the Market Unit.
People hired, on-boarded, paid, given feedback and developed in a timely fashion.
Ensure effective labor relations.
Act as trusted people champion ensuring that all team members are treated fairly and respected.
Facilitates a positive, productive and safe work environment at the front line...an exciting and rewarding place to work
Fosters trust and teamwork within the MU.
Credible advocate for PepsiCo values.
Support the MU team members with the implementation and sustainment of the new organization.
Coaching and Support of MU HR Team. Coach others to implement and sustain HR processes and tools.
Coordinate overall Best Practice tools implementation to ensure tool field readiness and people readiness/capacity for change.
Strategic HR Management & Corporate Affairs.
Enables the development of the MU manpower planning, staffing rewards and training & development plans (AOP).
Align performance objectives with AOP.
Lead and Manage CSR initiatives and business practices that benefit Jordan community.
Manage and coordinate government relations programs and initiatives (MOL, MOH, Municipalities, Charity agencies, NGOs, …)
Develop and maintain excellent external relationships with key government legislators, staff, trade association representatives, and other corporate government affairs representatives.
Monitor PR practices to ensure the right image for the company.
Provides coaching, mentoring, direction and leadership support to team members within the Corporate Affairs.
Ensure all product quality customer service and plant cost targets are met. Ensure all assets are maintained. Ensure all regulatory/local government/local union policies are met.
Customer: Execute core work, Product/pack changeovers, Product/pack quality, Trucks dispatched to order, Fleet hire/repair, Ensure product availability.
Plan Development and Execution: Asset preservation and reliability (plant & fleet), Plant costs to target.
Human Resource capabilities: Hire & develop front-line performers and management team.
Process Capability: Identify recurring problems for process improvement.
Develop and execute the yearly manufacturing plan (AOP) to deliver the business objectives (production volume, manufacturing controlled cost, safety…).
Establish and maintain a standard of performance for the operation. Strive for World Class results.
Insure the alignment of the manufacturing organization with the company vision, purpose and priorities
Manage the manufacturing operation consistent with the company operating values, & principles.
Establish individual accountability using coaching and support and performance management process.
Assess manufacturing operations staffing and skill requirements. Develop plans to address needs
Institutionalize manufacturing Best Practice Tools and Processes. (M&W 2000, PM, PA, CDF, etc)
Establish manufacturing priorities and allocate the resources.
Ensure product availability in the plant & Warehouses per production plan & ready to transport to DCs & Market.
Conduct Performance appraisal for direct reports & ensure it is done for the rest of the manufacturing areas.
Establish facility sense of urgency to get things done.
Prepare the ground for a brownfield plant start up.
Managing total plant operations and delivering superior customer satisfaction by driving results and exceeding expectations in the key areas of safety, service, quality and cost.
Direct Plant administration to ensure compliance to established policies.
Responsible for the cost and yield performance of the Plant in partnership with the overall P&L of the Plant.
Own and drive cost control initiatives and process control within the Plant.
Drive Safety improvements across the Plant.
Ensure the consistent execution of all SOPs throughout the Plant and in accordance with Global operations.
Develop a balanced approach to maximize best operational practices and cost efficiencies across the Plant while maintaining critical quality and raw material utilization standards that are necessary to maintain customer satisfaction and Plant profitability.
Implementing the output of the plant network optimization.
Drive compliance through teamwork for all Standard Operating Procedures within the Plant.
Identify and execute Lean opportunities to effectively eliminate waste.
Provide leadership to Plant staff to effectively recruit, train, develop, evaluate, motivate, delegate and monitor their activities.
Drive efficiency in asset utilization through proper transportation scheduling, dispatch, & driver management while meeting customer expectations.
Prepare the ground for a greenfield plant start up.
Lead team in defining a strategy for a suitable and profitable business for the plant. Translate policies, objectives, and strategies of the factory into short, medium, and long-term plans and programs.
Lead the team in preparation, communication and execution of the AOP (budgets), including financial framework, Best Practice tools implementation and sustainment, initiative calendar and people capability. Establish, implement and monitor general policies, plans and programs that are related to all departments at the operations/factory level.
Tracks overall business performance against strategy and adjusts plans / investments as necessary. Plan, organize, direct, control and evaluate the operation cycles; production department, quality assurance, costing, human resources, and logistics.
Institute Trimester Planning and Review process.
Coordinate the activities of various plant functions to ensure the most effective utilization of resources; plant, material and people.
Achievement of production plan to acceptable quality standards at a minimum cost, specifically to motivate employees towards higher quality levels of finished products.
Continually strive for improvements in material utilization and the reduction of spoilage.
Introduction of cost reduction/continuous improvement programs/processes.
Enable the team to implement and sustain Best Practice Tools that enables them to achieve the Annual Operating Plan (AOP).
Work with functional heads to identify capability gaps and agree on action plans.
Partner with functional leaders to define priority opportunities, access resources, and share learning's on initiatives' implementations.
Clarify roles, set performance standards and goals, and coach direct reports around the core work.
Role models and drives HR processes and tools to ensure value are delivered up through front-line. Implement human resources management practices that promote good labor management.
Ensure product availability, right quality, quantity, place and time to meet sales and marketing demand.
Manage warehouse and fleet assets and all distribution contracts to meet supply chain demand.
Develop and execute the yearly materials requirements planning, staffing, product sourcing, fleet and warehousing needs to meet the AOP objectives.
Prepare weekly production schedules and update in co-ordination with production manager to maintain safety inventory levels.
Coordinate the ordering of all raw materials; ingredients, packaging, fuel... to ensure adequate supply to cover all production needs.
Coordinate finished goods movement to distribution centers to maintain safety inventory levels across the system.
Utilizes visual factory concepts to control and organize the work.
Set warehousing/logistics/Fleet performance standards and aligns organization.
Coaches and provides constant feedback for development and improved performance.
Leads problem solving activities for warehousing/logistics operation; coaches on process improvement.
Co-ordinates warehouse resources across all facilities.
Ensure safe operating conditions exist throughout the warehousing operation. Promptly correct unsafe conditions.
Coordinate product sourcing within Market Unit to ensure product availability in the right: place, time, quantity, and quality.
Develop procedures to eliminate loss or damaged product in warehouse and during transportation.
Develop staffing and skill building plans for the warehousing/logistics operation that directly links to AOP objectives. Work closely with HR for effective implementation.
Responsible for the selection, on-boarding and recommending for termination of warehouse/logistics/transport personnel.
Ensure spare parts are available within as agreed on budget plan.
Setting department goals and objectives and work on attaining such goals.
Assist in dispensing advice, guidance, direction and authorization to carry out major plans and procedures.
Participate in preparing and executing department budget for spares, consumables and major equipment overhauls (R&M, Capex), and to ensure implementation of maintenance policies, procedures and routine.
Organize a new computerized system to update all preventive maintenance works for all lines.
Ensure filler speed is within optimum. Organize a new computerized system for mechanical downtime per area analysis.
Performs the analysis & identify the maintenance function priorities & goals to achieve production needs & improvement of quality.
Ensure the right implementation of preventive maintenance to keep the production lines efficient and upgrade within a certain cost.
Prepare and follow up long and short term maintenance planning and overhaul programs.
Work methods, policies and follow up procedure such as change over, and making sure that it is done the right way and try to reduce the time with coordination with production department.
Ensure safe operation conditions exist. Promptly correct any unsafe conditions.
Set maintenance team performance standards and aligns the rest of organization (Staffing & organizing).
Overall operation and management the department, including planning, organizing, lead problem solving activities and coaches the maintenance team on process improvement.
Recruit, develops, and improves skills for a capable maintenance team, and ensures they follow rules and regulations.
Controlling the operation and performance of each piece of equipment as well as the functioning unit as a whole.
Quality control and plant testing programs to assure that the final production prescribed standards, the production lines and processing systems are functioning properly.
Recording data and using this data to enhance the plant's ability to eliminate problems before they occur.
Using data to confirm that corrective actions or steps taken to improve efficiency have been successful.
Production and materials planning.
Assure efficient labors and labor planning.
Prepare all reports and fill all the needed papers for work.
Ensure of no waste of material or supplies on the lines.
Managing the whole maintenance department & Coordinate the daily activities.
Working closely with colleagues to maintain high efficiency of operation.
Repair a broad range of Bio-medical, Electrical, and Mechanical instrumentation.
Maintaining quality control of works. Prepare the daily progress reports.
Check and supply all spare parts, and materials.
Preparation of manpower budgets to meet organizational requirements.
Plan, conduct and coordinate performance management program.
Develop and coordinate the succession- planning program.
System operation and maintenance of all the equipment and machines used in the manufacturing of pharmaceuticals and hard gelatin capsules, as well as air conditioning equipment and general maintenance.
Perform troubleshooting down to component level.
Repair a broad range of mechanical instrumentation.
Provide preventing minors and major's maintenance per manufacturer's specification.
Testing, verifying, and evaluate new machines: MG2, Uhlmann, Manesty.
Faculty of Engineering and Technology (1989-1994)