Production Process Improvement Manager
Elsewedy Electric
Total years of experience :14 years, 7 Months
- Measure the OEE (Overall Equipment Effectiveness) for all machines and identify the potential opportunity for improvements to increase the machine performance and availability
- Reviewing the standard routing to create the best production routing
- Create a VSM “Value Stream Map” for the whole process to eliminate waste and optimize the lead time
- Proper communication with operation depts. (Production, Planning, Quality, Tech office, ...) to help in identifying blockers to overcome.
- Verifying the need for new capabilities & participating in acceptance and evaluation.
- Performing machine debottlenecking & continuous improvement projects.
- Provide a methodology to calculate an accurate production process time for the financial department
- Following all new product design capabilities and new materials trials.
- Implemented lean philosophy with a low level of automation or robotics options.
- Reduced the costs of some of the improvements activities and create value analysis that saved 10, 000, 000 LE Annually.
- Applied lean methods and tools that increase efficiency & reduce cost without compromising on Quality like (5S - OEE - Problem-solving techniques - SOP - etc.….).
- Participated with the operation team to ensure the lean concept was applied in all operational activities.
- Oversee the implementation of continuous improvement for (14) projects within the company.
- Supported Process engineers to improve Cycle time, Throughput time, and Lead time to a faster flow.
- Introduced standard lean training and workshops to all levels of employees within the company, for Example (5S - OEE - Problem-solving techniques - SOP - Kaizen).
- Identify and recommend the opportunities for improvement in different manufacturing & non-manufacturing areas.
- Leaded lean activities to ensure all operation K.P. Is are achieved Safety, Quality, Cost, and Delivery, and People Reduced the standard Scrap from 2.7% to 2.4%.
- Participate and guide the operation teams through standard Problem-Solving Techniques (8D Technique) to prevent problem recurrence.
- Optimized costs in the manufacturing process by supporting production and maintenance teams with lean tools.
- Managed various cross-function teams to apply waste elimination program and 5S approach in all processes.
- Managed Kaizen activities to promote the best fit and business-supportive ideas to be implemented.
- Decreased the Breakdown time for the machine by making adequate maintenance in adequate time
- Provide optimum annual preventive maintenance plan according to each machine's depreciation and workload
- Saving machine part cost by continuous follow-up and lubricating the important parts of the machine and oils changes
- Provide optimum quantity of spare parts to don’t stop the production
- Draw and redesign an important machine part to increase the lifetime and decrease the cost.
- Monitor the necessary parts depreciation and make root cause analysis to eliminate overconsumption and decrease the machine breakdown.
- Make a schedule predictive measure for the critical machine parts to be prepared before failure.
- Participated effectively in trials of materials, cable approvals, and Machine commissioning.
- Assured that all productivity-raising projects are moving properly as per plans.
- Proper communication with operation depts. (Production, Planning, Quality, Tech office, ...) to help in identifying blockers to overcome.
- Worked with Tool Shop engineer to decrease the tools preparation time to enhance the manufacturing process time.
- Created/maintained standard speed per every single item on every single machine/process.
- Created/maintained best practice changeover by machine level.
- Created/maintained updated routing criteria sheets.
- Followed the creation/updating of processing data sheets (PDS).
- Followed the creation/updating of Standard operating procedure (SOP).
- Worked on and solved methodology non-conforming cases (Concerning process capability).
- Followed shop floor Trials helping create additional material suppliers or develop new cable(s) or approvals.
- Sited/updated technical scrap values for different processes on different machines.
- Made/reported the OEE index for production lines on a frequent basis.
- Improved setup times.
- Improved machine performance by increasing running speed/ solving restrictions on production lines.
- Verifying the need for new capabilities & participating in acceptance and evaluation.
- Performing machine debottlenecking & continuous improvement projects.
- Process time calculation in the inquiry quotation stage.
- Following technical office modifications and updating corresponding process time.
- Arranging with R&D engineers to develop currently used programs to save the time of getting info from the tech office and achieve better quality.
- Created/updated Standard operating procedure (SOP).
- Monitoring cable manufacturing Process and highlighting the places where there are development chances in either increasing speeds or decreasing setup and stoppage times.
- Machine calibration to identify the actual outputs and compare them with specs.
- Calculating machine efficiency to be considered in machine loading.
- Following enhancements that happen on machines and studying the effect of it on machine speed and machine outputs.
- Participating with production in trials for completely new products or developments in any of the cable stages and also in approving new suppliers.
- Revising Sales standard lists, updating them, and extending them regularly.
- PDS information updating.
- Monitoring SCADA system speeds for all machines and recording the optimum speed for each cable.
- Maintaining the extrusion tools inside the tool shop.
- Responsible for monitoring the production phases and correcting any deviations from the production plan
- Follow up on all the production phases.
- Assign responsibilities to the technicians and labor according to the production plan.
- Evaluating the production problems and providing proposals for solutions.
- Following up the equipment maintenance.
- Cooperating with the maintenance manager in determining and identifying the needed spare parts' technical specifications.
- Preparing a daily report to be presented to the factory manager offering the product yields.
- Determining the employee’s performance standards, following up & evaluating their performance according to the predetermined performance standards.
doing the maintainable work for a very used machine and design and produce a spare parts for this machine
preliminary and detail design of mechanical and c.n.c. machine and production engineering