Project manager
Procter & Gamble
Total years of experience :31 years, 5 Months
Regional Project manager to build a green filed Hair Care manufacturing facility including facility, infrastructure, making, packing, warehouses and Utilities. Project capacity is in the range of 30 million cases per year. Role covers all project phases; feasibility, conceptual, detailing, execution and startup. Project team includes a diverse P&G multi-functional team, P&G contractors and local General contractor. The challenge involves design & recruiting the right staffing, selection and developing the right Engineering office for project design, selection and developing a local general contractor with required skills in execution, safety & quality control in a developing country with lack of resources in many areas.
Managing an ambitious program to develop local suppliers to supply raw and packing materials used in Dammam Plant. This Program will generate annual savings of 15 million US$, simply the current supply chain for raw and pack materials and improve company cash flow position.
Leading Beauty & Grooming Initiatives Pillar across Europe, Middle East and Africa region with total of 15 Plants operating across the region while maintaining previous responsibilities in Hair Care Business Development in Dammam Plant ( Responsible for Hair Care business development including products and packaging new initiatives, Capital management and Technical support for new products and /or packaging).
Responsible for Hair Care business development including products and packaging initiatives, Projects management and Technical support team for new products and /or new packaging. Over the past 2 years I've managed a team who delivered more than 50 initiatives and 30million US$ of projects. Shampoo brands include Pantene, Head & Shoulders, Pert Plus, Herbal Essences and Silvikrin. We serve more than 20 markets and produce more than 22 million cases per year.
Managing the overall operations of projects to blend, mix, process and package a wide range of Laundry detergents (Tide, Ariel, ..etc), Shampoos (Pantene, H&S, Pert Plus, Herbal Essences, Silvikrin), Dish washing liquids (Fairy), Fabric enhancers (Downy) with an annual budget of >20 Million USD in 2 production sites: Dammam & Dubai.
Responsibilities:
• Improve Plant organization design and performance.
• Manage wide range of projects with annual budget of >20MM$. Range includes making process, packing equipment, and facility related including 5 years forecast.
•Ensuring compliance with all pertinent laws and regulations governing the Safety, Health and Environment systems, this includes maintaining working rapports with inspectors for integrated risk management purposes.
•Proper functioning and standard maintenance of plant assets and instrumentation, coordinating machinery repairs, preservation contracts and facilities up keeping.
•Leading manufacturing and packing technology implementations.
Achievements:
•Re-engineered the total Plant organization.
• Deliver total quality projects meeting predefined success measures (cost, lead time, vertical startup, going to going target, safety, inventory, scraps, ... etc) as per P&G norms. Examples; Dubai new grass route site, Consolidation of Morocco shampoo volume in Dammam plant, laundry packing capacity increase, Local production of Herbal Essences shampoo...etc
•Conceptualized and accomplished the final production of a wide range of brands in Laundry (Tide, Ariel, Deepio, and Bonux), Hair care (shampoos; Pantene, Head &Shoulders, Pert plus), Dishwashing (Fairy) and Fabric Softeners (Downy).
• Re-engineering the Plant organizational structure to improve business processes and resolve bottlenecks in operations functioning.
•Active member in the Plant leadership team, devised strategic plans that had critical impacts on business growth and expansion. Cover for plant manager on many occasions.
Held a management role, monitoring working conditions and implementing and developing special projects to improve safety performance, health and environmental standards at the PG Factory in Dammam.
Achievements:
•Provided leadership in growing a safety conscious culture, applying programs related to: Industrial Hygiene & Safety, Fire Protection, Process Safety, Pressure Vessels, Electrical Safety, Thermal Safety, Enzyme Hygiene, &Environmental Protection in a factory with more than 500 workers and a replacement value of more than 240 million US dollars.
•Ensured that world class industrial hygiene standards where met, devised plans to eliminate accidents, guaranteed that adequate protection equipment was used throughout the facility.
•Developed and coordinated site training programs on: HIS, Process Safety, Electrical Safety, Technical Safety, Fire &Environmental Protection as a certified Procter & Gamble lecturer.
•Successfully led the plant efforts to upgrade enzyme program capability both in hardware &software terms, monitored reaction processes and transfers of products in conformance with safety procedures.
•Held open communications on precaution related issues with employees and built a competently harmless and protected organization benchmarking results across P&G World.
Special Recognition:
•Health, Safety, & Environment Annual Award, 1997, Proctor & Gamble, Cincinnati, USA
•Recognition letter with one-month salary bonus, Proctor & Gamble, Jeddah
•P&G 50 shares award.
Managed complete life cycle of projects for laundry, dish washing and shampoos manufacturing and packing technologies from initiation till completion phase, within requested budgets and time-lines with an annual budget of >10MM$.
Achievements:
•Coordinated facility related projects for expanding warehouses, relocating offices and erecting new buildings with sound engineering decisions, adapted total quality management approaches and applied competitive cost saving measures.
•Embarked on assessment and administration duties ranging from testing, installation, data interpretation, report preparations, resource management and proposal writing as a qualified project manager
•Controlled expenses and generated more than 0.8 million USD in net savings using expert judgment and field knowledge to minimize projects financial overload and completion within expected standards.
Successfully Completed Projects with total value of 14 Million USD:
•New mixing unit for Syndets making
•Warehouses Expansion
•Improvement Projects
•Ariel CBH Upgrade
•Polybags Packing line
•Pert for Kids Shampoo
•Enzyme hygiene Capability Upgrade
•Fire Protection systems Upgrade
•Tide formula Upgrade
•Fairy indented bottles
•Fairy Dumpy Bottles and many others.
Pioneered the design and installation project for Laundry making and packing Dust control systems to meet Enzymes’ hygiene operational guidelines, completed the assignment successfully protecting people and upgrading equipment to attain a capability of 8+/10 vs on a PG scale.
•Developed flexible and integrated manufacturing systems and procedures for this project, studied new machinery and recommended efficient combinations
•Conducted researches and implemented programs to determine optimum inventory levels for production and to allow optimum utilization of machinery, materials and resources
•Completed time studies and work simplification programs, analyzed costs of production and determined human resource and skill requirements.
•Monitored the reliability and performance of plant facilities, administrative systems and applied maintenance standards, schedules and programs.
Supervised programs to achieve the best use of equipment, human resources, technology and mechanical materials and procedures to enhance efficiency and productivity for synthetic detergents.
•Embarked on upgrade projects for the synthetic making department systems including; weighing systems, addition systems, and finished product quality variations.
•Measured load of chemical ingredients, calculated losses, savings and quality as an active member of the department team.
•Collected samples and performed routine chemical and physical tests of products, adjusted processing machines and manufacturing equipment as necessary.
•Substantially improved reliability success measures across the board (PR, MTBF, MTTR, cost, ...etc.)
Worked on a significant project to develop an RI Solar and Radiation meteorology operating station, duties included: regulatory inspection, calibrations, software development, quality control & analyzing generated data to generate forecast models.
•Researched station’s acquired data and analyzed information dating 10 years.
•Developed a spectrum of engineering & meteorology software including a statistical weather forecasting program.
•Supervised senior projects &summer training students from the Mechanical engineering section. Composed technical proposals for clients and published 6 scientific articles in globally recognized journals.
SCIENTIFIC PUBLICATIONS:
•Abdel-Nabi D.Y. & Elhadidy M. A., 1991. A statistical model for minimum temperature forecasting at Dhahran, Saudi Arabia. ENERGY V16, No 4, pp. 771-778.
•Abdel-Nabi D. Y., Zubair S.M., Abdelrahman M.A., & Bahel V., 1990. Regression analysis for residential air conditioning energy consumption at Dhahran, Saudi Arabia. ASHRAE transactions.
•Elhadidy M.A., Abdel-Nabi D.Y., & Kruss P.K., 1990. Ultraviolet solar radiation at Dhahran, Saudi Arabia. Solar Energy.
•Elhadidy M.A. & Abdel-Nabi D.Y., 1990. Diffuse fraction of daily global radiation at Dhahran, Saudi Arabia. Solar Energy.
•Kruss P.K., Bahel V., Abdel-Nabi D.Y., & Abdelrahman M.A., 1989. Estimation of total radiation at Dhahran, Saudi Arabia, ASHRAE A, B, & C technique. ASHRAE Transactions V95, part 1, No 3240.
•Zubair S.M., Bahel V., Abdel-Nabi D.Y., & Abdelrahman M.A., 1989. A case study for improving performance & life expectancy of air conditioning systems at a University campus. ASHRAE Transactions V95, part, No 3195.
Commenced an academic career as a research assistant in the Mechanical Engineering department, worked on significant field projects and completed scholarship studies to obtain a masters degree in 1986.
Research Projects:
• Monitoring & analysis of solar radiation & weather parameters at Al-Fadhly research & development farm. Ministry of Agriculture, Saudi Arabia.
• Electrical Energy Conservation on KFUPM campus. Ministry of Higher Education, Saudi Arabia.
• Solar radiation & meteorology monitoring station. Energy research laboratory, KFUPM, Dhahran, Saudi Arabia.
• Gained valuable experience as a Trainee in the Electricity company after being awarded a scientific distinguish graduation medal from the university of Yarmouk
• Received a college fee waiver for three years as an award to honor role first place students.
PROCTER & GAMBLE CERTIFICATIONS: • Certified Advanced Projects Manager • Certified Process Safety Engineer. • Certified Electrical Safety Engineer • Certified Industrial hygiene & safety program Leader • Certified Environmental protection program leader • Certified Technical safety program leader • Certified Fire protection (Class 1) program leader • Certified HS&E program leader • Certified Environmental control program leader • Certified Hygiene Engineer • Passed Radiation protection principles short course • Passed Ergonomics Training short course • Reliability Engineering School MANAGERIAL TRAININGS: • Managing Organization Effectiveness • People Supporting People • Interpersonal managing skills • Implementing total quality (trainer) • Memo writing (trainer) • Achieving quick change over • People developing College • Positive Power & influence • Negotiation strategy & tactics • Selection interviewing • HPWS Organizations • People & communications skills • Daily management systems • Organizational performance model • Integrated Work Systems (IWS) • Maximize Creative & logic thinking • Initiative management • Progressive maintenance • Atonomous Maintenance