Plant Manager
Al jawhara for corrugated board and printing company
Total years of experience :16 years, 10 Months
Success to oversee plant operations such as budget, production schedule and stock and Maintain machines and improve customer service levels with improve products quality, optimize staffing levels interact to cooperation with production & Maintenance engineers, planning, quality, sales as well as the manufacturing technical team to Produce and carry out development plans covering working areas and staff
Success to increases production from 1100 Ton/ month 16 Hrs. to 1700 Ton /Month 13 Hrs.
Success to decreases the total average waste from 17% to 11 % of total production operation processes
Success to increases the production quality which decreases the refuse from 5% to 1.5% from total productivity
Achieving KPI targets - Ensure targets are set within the working areas to meet strategic targets and plans
Setting Operational costs and controls, Labor costs and controls, Control of budgets and Maintain and improve direct labor costs percentages and cost of production and distribution, and prepare and execute departmental budget for staffing, spares, consumables, major equipment overhauls and new initiatives.
Performed the analysis and identify function priorities and goals to deliver the Annual Operating Plan
Direct Health, Safety and Environmental activities to ensure compliance with current and future legislative requirements, and comply with internal quality controls and ISO QMS, Success to Achieve the BRC
Communicate business and Company issues to direct reports and engender a good team spirit
Ensure implementing Preventive Maintenance (PM) Steps for the plant as per the Total Productive Maintenance (TPM) agenda for the plant, and support implementing new maintenance programs to enable growth for future
Oversee major projects construction and installation activities.
Ensure that the maintenance workshop provides timely support to the production operation and other functions.
Ensure safe operating conditions exists throughout the facilities.
Success to increases production from 1800 Ton/ month 24 Hrs. to 2300 Ton /Month 16 Hrs.
Success to decreases the total average waste from 14% to 10 % of total production operation processes
Success to increases the production quality which decreases the refuse from 3% to 0.5% from total productivity
Ensure efficient maintenance and up keeping of all buildings, grounds and service & production equipment.
Develop the proper control procedures for maintenance such as work orders, work schedules, equipment listing, machinery which decrease
Institute an effective preventive maintenance program to ensure efficient production operation within cost targets.
Ensure implementing Preventive Maintenance (PM) Steps for the plant as per the Total Productive Maintenance (TPM) agenda for the plant.
Support and Assist production teams to deploy AM steps through improving the overall equipment condition (restore basic condition).
Support implementing new maintenance programs to enable growth for future
Consult with production personnel to determine equipment operating and maintenance needs.
Ensure that the maintenance workshop provides timely support to the production operation and other functions.
Ensure safe operating conditions exists throughout the facilities. Promptly correct any unsafe conditions.
Success to Achieve the BRC
Set maintenance team performance standards and align the organization.
Coordinate maintenance resources across facilities.
Coach and provide constant feedback for development and improved operation.
Utilize visual factory concepts to control and organize the work.
Develop staffing and skill building plans to build technical mastery.
Lead problem solving activities and coaches the maintenance team on process improvement.
Assist in the coaching, mentoring and implementation of the Health & Safety programs in the field
From March 2013 and Till now as Maintenance, Installation and Repair Manager at IN Pack for Packing
* Analyzed the Department maintenance process based on historical data and questionnaire results which led to the identification of the weak points& machine down time in the system.
* Designed Information System; database and program logic for machine down time.
* Decreased equipment failure and spare parts consumption like pneumatic cylinders, control valves and air bellows by application of dryer system for air cycle.
* Worked as a TPM (Total Productive Maintenance) coordinator for the Utilities section (compressors, boilers, glue lap, ink lap, balers).
* Increase the utilization of manpower as possible as by having a monthly & annual plan, good preparation and storage of spare parts and monthly training of technicians.
* Supervised the start up and operation of corrugators, printing and stitching lines.
* planning the maintenance schedule and machine spare parts.
* Install and repair machines and spare part as machine manual request.
* Supervision of mechanical team to make overall corrugators machine lines.
* Order the machines spare parts from local and the foreign of suppliers places.
* Supervision of mechanical team to make overall flexo printing machine lines.
* Supervision of mechanical team to make overall rotary feeder and vacuum feeder.
* Supervision of predictive maintenance for corrugators’ lines and printing machine.
* Supervision of preventive maintenance for corrugators and printing machines.
* Supervision of Maintenance for machines includes the following in old position.
* Supervision for inspector for quality of product to be known the machine state and sure about quality of each part of machine work in good condition or replacement in periodic maintenance or corrective maintenance.
* Designed frist manual slitter scorrer was work by using a used cleen cut knife from corrugators and anvil was used from printing
* Designed Information System; database and program logic for machine down time.
* Analyzed the Department maintenance process based on historical data and questionnaire results which led to the identification of the weak points& machine down time in the system.
* Applied Analysis techniques on the machine that helped in the study of an expansion the available time of machines product and save machines state.
* Managed maintenance, repair & troubleshooting of mechanical Equipment including corrugators, printing machines, boilers, softeners, compressors, pumps, cooling towers.
* Prepare and manage an annual spare parts process of all corrugators and printing lines.
* Increased technicians’ motivation by redesigning the workshop layout, improving workshop facilities and application of QCC (Quality Control Circles).
* Decreased equipment failure and spare parts consumption like pneumatic cylinders, control valves and air bellows by application of dryer system for air cycle.
* Worked as a TPM (Total Productive Maintenance) coordinator for the Utilities section (compressors, boilers, glue lap, ink lap).
* Increase the utilization of manpower as possible as by having a monthly & annual plan, good preparation and storage of spare parts and monthly training of technicians.
* I help forgot ISO (TUV) mark in February 2011 for maintenance department.
* planning the maintenance schedule and machine spare parts.
* Install and repair machines and spare part as machine manual request.
* Order the machines spare parts from local and the foreign of suppliers places.
* Supervision of mechanical team to make overall flexo printing machine lines.
* Supervision of Maintenance for machines includes the following in old position.
* Annual analysis of faults and down time for all machines and all section of machine.
* Help for install some Machines.
* Preventive & corrective Maintenance corrugated cardboard and printing machines.
* Maintenance Compressors, machinery packaging, scrap pressing.
* Maintenance an air Conditioner, Refrigerators, chillers.
* Implementation planning daily, weekly, monthly maintenance.
* Implementation preventive maintenance for corrugator, printing machines.
* order the machines spare parts from the local and the foreign suppliers.
* Implementation Maintenance machines include the following machines: -
1- Corrugated Board or Carton machines Single facer like (Peter, Compact star, BHS, Agnati, Hsieh Hsu), Auto Splicers, mill roll stand, preheaters, glue machine, double backer, max cut, slitter scourer, cut off, auto stacker, conveyer system.
2- Flexo printers for corrugated box rotofeed like (3 machines Ward Flexo stacker, 2 machines TCY folder gluer, SBL stacker, LIAN TIEE folder gluer).
3-Air Planet (Screw Compressor's (5 kaeser, 1 Atlas Copco), 3 dryer Atlas Copco, Reciprocating Compressor, Safety Valve, air tank, air filter, gages).
4- Strapping machines (semi & fully automatic) Mosca.
5- Stitching machines (manual & semi Automatic) God-Swill.
6- Formatting machine vacuum feeder "Flat Bed Die Cutter" (Y T I 1700 SII).
7- Samples machine "Plotter for Corrugated board samples" (ZUND).
8- Pumps (Diaphragm Pump- Screw Pump - Axial Piston Pump-Reciprocating Pump -Rotary Pump - Gear Pump - Van Pump - Plungers Pump - Piston Pump)
9- Maintenance of Hydraulic and Pneumatic Systems.
10- Maintenance of generator (caterpillar).
11- Maintenance of heavy equipment machines.
12- Maintenance of firing system.
Academic Degree: B.Sc. of Engineering University: Menoufia University Major: Mechanical Power of Engineering Faculty: Shebin El-Kom Faculty of Engineering Graduation project: Cold flow Simulation for Solid Rocket Motor Chamber Grade: Excellent Graduation year: 2007
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