Factory Manager
Shyaw Dairy & Ice Creme Industries
Total years of experience :24 years, 5 Months
Shyaw, it’s specialized in production and sales of yogurt, cheese, cream, doogh, & ice crème.
My responsibility was but not limited to Managing and supervising all departments of the factory and contribution in strategic planning and decision with the top management. On the other hand, overseeing all aspects of a dairy operation. Involved in everything from hiring and training employees to purchasing supplies and equipment, developing new products, and ensuring that the business is operating efficiently and profitably.
Responsible for ensuring that excellent customer service standards are met; managing, training and developing supervisors and coworkers; completing daily and weekly paperwork; creating work schedules; reviewing time records, writing performance appraisals; following and enforcing all company policies; maintaining the Dairy’s high standards of working conditions - (cleanliness, safety, quality, security, inventory and delivery).
Bureida Trading & Refrigeration is one of Al-Munajem Group, it has specialized in PUR foam-sandwich panel production for cooling solution as well in manufacturing the reefer boxes, cold rooms and cold stores.
Mainly I am concerned with improving the company's market position and maximizing its financial growth, by using appropriate measures, analysis and evaluation methods to accurately identify and document improvements related to Continuous Improvement delivery of the business.
Developing key growth sales strategies that impact the revenues, growth in terms of business expansion and profitability by building strategic partnerships and making strategic business decisions, moreover, implementing and control the Prospecting, Forecasting, Incentive program, hiring and training team members evaluating and adjusting performance, prepare bids costing and pricing for proposals, quotations & offers etc.
Key contribution and achievement include but not limited to:
- Re-engineering and product cost reduction
- Sales growth significantly through the last 7 months of 2019 contribution by 52% respect to 2018 sales.
- Exceed the ‘6 month’ sales target in 2020 within 5 months only.
- Increasing the customer base by 15% in the early 2020
- Contributed to raw material negotiations for key project resulting in 6% additional profit.
- Identified “bottlenecks” and implemented new and improved processes and policies.
- Built customer acquisition strategy that generated consistent monthly growth of at least 12%
As a result of my oriented professional with fruitful years demonstrating year-over-year improvement of cross-functional experience which have been invested to offer and provide a consultation services to the industrial organizations.
I have invested my solid cross-functional experience to offer and provide a consultation services to the industrial organizations to help them improve their business performance in terms of operations, profitability, management, structure and strategy by using appropriate measurement, analysis and evaluation methods to accurately identify and document improvements related to Continuous Improvement delivery.
Key contribution and projects that I have involved in, include but not limited to:
- Provide strategic support to the leadership team, including project planning and management, coordinating initiatives and special projects, between senior leadership and their teams.
- Direct cross-functional teams and facilitate efforts to build new business strategies and streamline processes.
- Develop presentations from conceptual information to completion as well as competitive analysis.
- Analyze performance data to measure productivity and goal achievement.
- Implementing Balance Scorecards as a strategy tool to control the strategy progression.
- Implementing operations excellence as well as the lean concept at the organization.
- Conducting research and surveys to gain understanding of the business analyzing statistics.
Alessa is an integrated group in the cooling business including distributing appliances, electronics and manufacturing refrigerators, freezers, air conditioners packages & air handling units, as well as contracting and installation of personnel and commercial air conditioners (Concealed & Cassette Package) and air handling units.
Mainly, I am concerned in direct and manage all day-to-day processes for Air Handling Unit Factory ( (AHU : customized design air handling unit AHU is normally a large metal box of insulated PUR-Sandwich panel which connects to the ductwork that channels conditioned air throughout a building and returns it back to the AHU).
As well, supervise eight individuals and more than 150 people and Led efforts across sales meeting, production, quality, purchasing, shipping, receiving, commissioning and installation, design, planning, inventory and pull processes to accomplish projects within the agreed budget, quality and time line frame.
Allocate and manage strategic utilization and deployment of resources to achieve plant production objectives.
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Achieve the overall organizational and financial objectives by assuming responsibility for setting and controlling budgets, targets and objectives (KPIs), providing regular reports on progress to the President, analyzing, highlighting variances and recommended corrective and preventive actions.
Key contribution and achievements include but not limited to:
Sales growth significantly through the 3 years of my contribution while achieving year over year "YOY" sales growth @ 85% in 2013, 105%in 2014 and 41% in 2015.
Productivity improvement more than 450% by designing and creating several industrial ideas, methodologies and tools to support the production, eliminating the bottle necks and improving the productivity at most of the factory shops and minimizing the scrape by 12% which in turn reduced manufacturing lead times by 65%
Realization factor improvement drastically by more than 100% to reach RF=1
Adding advanced technology machines to speed up the output with very minimal labor cost like Reduced the cost of unit by 4% - 5% through implementing a cost reduction program which mainly focused in material design, scrape %, processing, man hours & resources.
Freudenberg is a joint venture company, 70% hold by a worldwide German company of producing a high quality mechanical household product \[Brushes, brooms, dust pans, mops, scourers (scrubbing abrasive and sponge material), wipers, etc.\] through injection & extrusion molding.
Key Responsibilities’
• Mentor, direct, coordinate, led and develop a top performing team of 200 employees, seven engineers and 5 sales man in the management of the smooth and efficient daily functions of a plastic house hold products and cleaning items factory to achieve the annual targets and maintaining high quality standards and HSE standards at workplace .Manage all the operations of the plant (including production, maintenance, facility, warehouses, Quality, planning, performance review "KPI's", costing & budgeting, procurement and sales ) and provide the technical support and advice for manufacturing, sales team and marketing teams.
• As well ensure optimum utilization of materials, labor and equipment to maximize productivity in addition to review processing schedules and production orders to make decisions concerning inventory requirements, staffing requirements, work procedures, and duty assignments, considering budgetary limitations and time constraints.
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• Direct and oversee an organization's sales policies, objectives and initiatives. Set short- and long-term sales strategies and evaluate effectiveness of current sales programs. Recommend product or service enhancements to improve customer satisfaction and sales potential.
• Determine annual unit and gross-profit plans by implementing marketing strategies; analyzing trends and results in addition to implement a sales demand generation plans.
Key Contributions & Achievements
• Successfully set up the new production plant at Anand, Gujarat - INDIA, comprising Extrusion line, Injection machines, Brushes/brooms making machines & associated Utilities within 5 months
• Successfully established the HSE programs and achieved Zero accident result for one year of working
• Improve the key performance indicator OEE of the equipment by 20% at the end of first year.
• Successfully achieved 108% of sales target at the end of first year.
• Market survey analysis and launching a new five innovative items to generate more sales demand
• Reduced the quality complaints of products significantly (by half) at the end of first year
• Improved the cooling rate at molds to reduce the cooling time by more than 12% (Idea was: adding cooling tower to the plant to cool the Hydraulic oil of the injection machine separately and keep the chillers run to cool the injection molds and extrusion line)
• Consistently achieved on time delivery targets (deviation between planned delivery date and actual date reached zero in the last quarter of first production year)
Freudenberg Vileda is a joint venture company, 51% hold by a worldwide German company of producing a high quality mechanical
household product \[Brooms, wipers, Buckets, Scourers (Abrasive and sponge), etc.\]
In charge of overseeing all operational tasks and activities for the production of a plastic house hold products and cleaning items
factory to achieve the annual targets and maintaining high quality standards and HSE standards at workplace. Manage all the
operations of the plant (including the entire production, planning, production schedules, deliveries, quality, stores, budgeting,
HSE (Health safety & Environment), training, development, operational budget, facility & maintenance. More over manage the
demand planning interaction and communication with Procurement, Customer, and Manufacturing functions to ensure
effective capacity and raw material planning. Define and establish company’s quality procedures, testing methods, sampling,
standards and specifications; as well as evaluate adequacy of quality assurance standards to meet the TQM objectives and
requirements.
Enforce HSE standards (OHSAS 18001, ISO 14001), company safety standards, government regulations, etc., and manage
compliance thereof while communicating Company HSE policies, procedures, and ensuring they are understood and adhered
to, at all Company locations, to work towards an incidents free work environment
Achievements
* Increase the Capacity utilization of the plant by >50% during the 1st year of joining
* Reduce the PET waste significantly by 8.6% contributing to a saving of more than 12, 000 Euro per year in material cost and
logistics cost as part of a cost saving program since 2008 till today
* Reach the sales targets (100%) by utilizing the work force efficiently & the maximum capacity of equipment’s effectively through a
day-to-day updating of production plan, schedules. In addition to daily production control, implemented a productive maintenance
program & production sequence development
* 100% reuse of recycled plastic in sub parts by instead of using expensive version plastics
* Improve the productivity of plastic injection parts by 5% -10% by redistributing the cooling lines into the molds
* Increase the OEE (Overall Equipment Effectiveness) by more than 25% through reducing the downtime, change over time,
rejection which already decreased the overall electricity bill at the factory by more than9% approx. with higher production rate
MEC is a plastic products manufacturer having more than 30 injection machines, 260 moulds (hot runner & cold runner molds, multi
cavities, core puller technology, insert technology) and dealing with different grades of PP, HDPE, ABS, HIPS, PC, POM & SAN
Key Responsibilities
* Prepare and draft plan, schedule, job time scales and oversee production process
* Control production and inventories within the plastic factory to match the demand
* Preparing Time-Motion studies to capitalize on productivity improvement opportunities
* Review the employee’s performance and motivate them to deliver as per expectations
* Estimate costs and set the quality standards in addition to making sure that products are produced on time with the right cost and
are of good quality
* Effectively manage labor requirements/manpower planning, production planning, stock management, instrumentation calibration,
plant modifications and develop innovative systems and processes utilizing all available technology
* Extend technical support and advice for manufacturing and molds design and repair
Achievements
* Reduced the rejection of molded parts by more than 30% by adjusting the right parameters setting into the injection machine in
addition to improve the cooling water cycle
* Improved the cooling cycle of chillers by adding a storage tank (20 Cubic meter size) which reduced the cooling time by 10%
* Reduced the lead manufacturing time by 5% by building a stock of common items in the time of low demand to provide more
availability for the machines and molds during high demand season
* Reduced the size of sprue/riser (a useful part after ejection) to reduce the weight by 5%-20% for each cold runner mold
* Reduced the cycle time of injection cycle by 10% approx. for two molds. The idea was: upgrading two molds to be run automatic
instead opening the machine door and get the molded part manually by adding a blowing air valve/ejector assembly. This means 5
pieces more per hour or 10% improvement in productivity for each mold
Bacholer Degree / Mechanical Engineering
