Quality Control and Production Planning Section Head
YAMAMAH STEEL
Total years of experience :21 years, 7 Months
Built a Quality system from scratch, and get SASO Certificate, also prepare to get ISO 9001-2008 Certificate.
Responsible for Quality Control team which start inspection from Imported or Received Billet (incoming inspection) such as “Chemical Analysis test result and review with supplier certificates, Billet Dimensions, Camber, Rhombadity, Surface Defect”, Quality Control Process (in process inspection) such as “Reheating Furnace Temp., Stand Area Temp. at Rolling Mill, Recovery Temp. (After Quenching Box) and Final Product Inspection (Finish Good Inspection) such as “Bar Dimensions, Surface Defect, No of Bars per Bundle, Mechanical Test, Bend Test, Chemical Analysis Test, Bundle Leveling, General Shape of Bundle” up to received to warehouse.
Part of team work which responsible for make trails and follow up Process of Quenching Treatment “Temp Core Treatment” for Gr40 online to satisfy Mechanical Properties of Gr60 for all sizes regarding to SASO 2/1992 and ASTM A615/M Standards.
Review all Quality Control shift reports and check all parameters for Mechanical properties, Chemical Composition and Rebar measurements, and Prepare QC Daily Report.
Support my Quality team work in all times to solve any troubles happen in our labs (ARL 3460 for chemical analysis, Instron Satic 150 ton for Tensile test & Portable Hardness test) or faced during in process inspection (in case of any Nonconformity).
Support my Quality team work at Identification of final product by “Zebra System” and Control the consumables from Labels and Ribbons.
Responsible to issue MTC (Mill Test Certificates) for Finish goods regarding to sales department required.
Simulate constrained demand plan regarding to International Standards "ASTM A615 M" or Saudi Standard "SASO 1992".
Investigates all customer complain and prepare the technical report for Quality Manager to satisfy and replay.
Also how Yield calculates and how we can achieve the target with reduction of cost and utilizes time “the actual available hours” for processes.
Responsible for calculate and follow up the productivity and efficiency of Bar Mill.
Demand Planning Obtain unconstrained demand plan from Technical & Sales Support and project prioritization from project management to Explore and develop system capabilities or recommend a suitable platform to be used for consolidating demand forecast.
Make adjustments to demand plan with inputs from sales and project management prior to monthly meeting.
Issue the Annual Plan depend on the Expected Demand Plan, and also responsible for issue monthly production plan and follow up the plan day by day and define the deviation and the reasons if it is found and discuss in the daily meeting with Project Manager.
Follow up and give recommendation for the actual situation for raw material status and review obtained raw material supply constraints from procurement and Consolidate current levels of raw material and finished goods inventory and logistics constraints from unit local schedulers.
Identify potential scenarios for production allocation based on constrained demand plan.
Monitor the performance of the local schedulers against projected targets so that areas of unsatisfactory performance are identified and rectified promptly and performance improvement opportunities are capitalized upon.
- Member of the team which responsible for establish (level III) MIS.
- Responsible for create the Expected Annual Plan & actual monthly plan.
- Follow up raw material warehouse stock to can prepare the weekly schedule for Steel Making Plant (SMP).
- Follow up Semi Finished Product from each plant to schedule and utilize the weekly schedule to complete the strategy of monthly target for each plant.
- Arrange the replacement plan (more scenarios) in emergency cases to convert the schedule and utilized the time to cover our monthly or annual goal as possible as we can.
- Responsible for follow up the plan and make the priority orders recommendation according to Customer Order priority regarding Sales Order Expire Date, Row Material Availability and Customer Warehouse Status and Delivery Plan.
- The interface between Sales, Purchasing “foreign and local”, Productions “Melt Shop Plant - Rolling Mill Plant”, Finishing, Warehouse and Dispatch to manage the full cycle plan.
- Lead and motivate the central and unit planning teams
- Ensure that that the applicable machine outputs, backlogs and logistics constraints are being considered by local schedulers.
- Ensure that local schedulers comply with released monthly production orders.
- Ensure that cancelled orders are removed from schedules to avoid aggregation of uncommitted finished goods inventory.
- Responsible for check up the Export Remain Production to convert to anther export order or to local order for all different final Products in warehouse stock.
- I have experience to monitoring the operational and maintenance requirements of special steel processes as (NDT line, 3 MPI line \{the first for Billet, Semi Billet, the second for Round, Hexagonal, Square Shapes, the third for wire rod and fast samples of round bar during rolling process\}, Induction line (for heat treatments all special steel grades to satisfy customer requirement), Heat treatment Furnaces (Solution Furnace and Bogi Furnace to make (Normalizing - Quenching - Tempering - Annealing- …. Etc) treatment, also management and control of consumables.
- Internal Auditor ISO 9001/2000, ISO 14001/2004.
- I have experience to monitoring the operational and maintenance requirements of special steel processes as (NDT line “Non Destructive Test”, 3 MPI line “Magnetic Particle Inspection” \{the first line for Billet, Rolled Billet, the second line for Round, Hexagonal, Square Shapes, the third line for wire rod and fast samples of round bar during rolling process\}, Induction line (for heat treatments all special steel grades to satisfy customer requirement), Heat treatment Furnaces (Solution Furnace and Bogie Furnace to make (Normalizing - Quenching - Tempering - Annealing- …. Etc) treatment.
- Responsible for (Daily & Monthly & Yearly) Report for the QC Inspections Area (Steel Making Plant Insp., Rolling Insp., NDT Insp., Heat Treatment Insp., Final Insp.).
- Making daily check in the morning to visual review the daily production and what is the out of specification and follow up the corrective action.
- Applying of standard Specifications.
- The interface between the Quality Dept. and all departments in different plants, also the interface between the Quality Dept. and any external corporation activity.
- Statistical Process Control (Control Charts).
- Inspection to assure Quality requirements.
- Responsible for support my teamwork in Identification Final Product by Zebra System (Labels and Sticker).
- Responsible for support Portable chemical analysis "Sepectro Test" Operation and Maintenance.
- Responsible for creates Mill Test Certificates for customers.
- Internal auditor to assure the Quality system.
- Follow the internal audit according to internal audit plan which distributed for all determents.
- Prepare the questions from question list for every dept. auditing.
- Assure that all work instructions (Work Standard) are applied in quality dept. with all forms and all forms fill with data to get real record to get real data analysis.
- Assure that all equipments are already calibrated and all equipments use in the calibration list, and follow up calibration plan.
- Monitoring all spare parts of quality and lab equipments and follow up the situation of Purchasing Orders.
- Responsible for make review about the nonconforming report after internal audit.
- Follow up the correction, the corrective action (work & time), and the preventive action to assure that he nonconformity will not happen again.
- Prepare the quality manager meeting which discus the nonconformity.
- Prepare to the external audit by finishing all nonconforming (observation, minor, major) from latest external audit.
- Internal Auditor ISO 9001/2000, ISO 14001/2004.
B.S. "Computer Science & Mathematics", Faculty of Science, Suez Canal University, 2001. "Statistical, Numerical Analysis, Thermo dynamic, Nuclear Phisecs, Organic Chemistry, inorganic Chemistry, MIS, Data Structure, Programming Language, ...etc. Bachelor Project "Operation Research" with Excellent Degree.
