Quality, R&D General Manager
Best of France for Dairy Product Co. Lactales Egypt Group {B.C.C}
Total des années d'expérience :40 years, 4 Mois
Direct and manage the quality & R.D activity, to improve and reach the group strategy, and increase the productivity of the employees.
Achievements:
• Build up the quality team, for all factional require to increase the productivity, and cover all sides of the company to control all steps.
• Increase the tests on the finished product, during shelf life, with record to follow up the product history.
• Change the way of complain feedback, by introducing correction and preventive action.
• Update all SOP, and flow charts for actual processing running, up date all ISO certificate, and HACCP programe.
• Control the wastage of fat and protein, by running hourly sample test from Waste Water Treatment Station, to sort In Time Problem.
• Improve the quality of In Process Control record sheet per line, to improve the control on the products, and keep record for any problem during process and filling, to eliminate Non-Conformity product goes to the market.
• Follow daily CIP, and change the parameters and sequences of it for several line, to improve shelf life of final products.
• Implement and exuded the raw and packing materials specification manual, and WWTS manual.
• We awarded the highest score 85.5% in quality International Lactales audit over the Egypt group of the five factories.
• For R&D, I build team with learning them the R&D Methodology, and I introduced several products to the market such as:
1) Caramel pudding for Nestle Gold Brand, and Mehalabeah with Mesick for Lacteal brand.
2) Koshaf yoghurt drink for Ramadan month, and watermelon for summer time.
3) Chocolate and Cappuccino milk shake lunched, and several other direction of taste.
4) I reduced the cost of most of our product range to meet market challenge.
5) Finalize the Danish Feta cheese in tins 20 Kg project, and its technology for processing.
6) Introduce new White Cheese with 2.5% protein only, to give low price product with good quality to meet country requirement.
7) Introduce new yoghurt category called Greek Yoghurt.
8) Introduce new White Cheese with different spices type for President Brand, high quality product from UF technology raw milk.
• Lead and manage the factory to reach company strategy, and increase the productivity of the employees and equipment’s.
• Provide leadership for the successful day-to-day operation of the facility, and analyze workforce requirements.
• Review established production schedules for all manufacturing departments to insure established inventory levels are met while operating at the highest efficiency possible, and prepare Plant Budget and monitor operation expenses.
Achievements:
• Set a system for shift change and arrival time, to assist in keeping line running continuously.
• Reorganize the production weekly plan, to increase line efficiency, and reduce stoppage for C.I.P and utility usage.
• Improve OEE, and start lunching validation program for FSSC-22000, to improve procedures out-put and easy to learn for new stuff.
Operate, improve the performance and reduce the waste of the 2 factories \[Wafer, Chocolate, Biscuit, Gum and Candy\], review the 42 branches across KSA to improve work performance and quality, build up maintenance teams, and Implement quality system as concept
Achievements:
• The implementation of comprehensive quality system to be the pasic on work documentation, SOP have been clear in processing.
• Improve wastage, and quality of the chocolate factory and retail performance done successfully.
• Sales operation manual published, fixed plan to finish old packaging material stored, and exploit the storage capacity the best way.
• Assess the risks in the Royal factory to produce wafer and develop a plan for reprocessing and refurbished.
• Evaluation of old machinery done, and report to replace it because it unproductive actually, plan work according to the value issue.
• Reduce the wafer losses from 24 per cent to 3 per cent, and improve the out put by preventive mantinance program.
• The installation of new candy line and improve its performance by 30 percent and improve the efficiency and production time, for processing system improved by implement continues run instead of the patches.
• Reduce damaging product transfer by 7% from 9%, and use OEE for improve lines effacancy day by day.
• Development of specifications of raw materials and ready-made imported products, such as almond, raisin and dried fruit.
• Fix audit program for 42 branches and activate the ISO certification processing for ISO 22000 and HACCP with quality team.
Lead and direct the quality and innovation department, and build up the quality team around business functional.
Achievements
• Prepared the executive plan including targets and achievement time.
• Implemented and executed P&P, SOP’s, processing charts, cleaning and sanitation program.
• Successfully finished first stage study of the new herbal extraction line project.
• Successfully finished second stage of the new project (install line, commissioning and production) .
* Quality & Innovation Executive Director and Chief Audit Executive (Apr 2011 - Dec 2012)
Lead the internal audit department along with quality and innovation department
Achievements:
• Reduced the cost of the External Audit assignments by 50
• Reduced risk management operational and losses by 7%.
• Set Internal Controls by evaluated effectiveness and efficiency of business operation, reliability of financial reporting.
* Quality & Innovation Executive Director (Sep 2010 - Apr 2011)
• Lead and direct the factory, herd and agriculture quality and Innovation departments, develop and maintain appropriate policies, procedures, objectives and KPIs across the company functional. Reviewed and updated Quality Manual, HACCP and ISO-9001.
• Employed a measure to place quality at the heart of the Organization, by improved calibration record and tests methods.
• Reviewed all recipes and improved several products profile and standardized all raw ingredients.
Achievements:
• Set up a yearly executive plan with target and KPIs, which was successfully executed.
• Implemented supplier’s audit and score card program, leaded to improve our supplier’s service and listed back-up suppliers.
• Implemented and executed audit program for branches and clients, lead to improve the market complaints procedure and reduced the total complaints to 1:10000 instead of 1:1000.
• Implemented and executed G.M.P and G.H.P program across the company functional.
• Reviewed and updated policies & procedures to current across the company functional.
• Restructured main laboratory to perform different physical and chemical tests for Raw and Packaging materials and products.
• Initiated identification microorganisms program for micro lab, lead to reduce contamination, and save mixes by 4%.
• Reduced analysis cost per tons, from 23 S.R to 9.0 S.R.
• Implemented “On Time On Full” program to improve deliver the test results from 27 minutes to 15 minutes.
• Executed hygiene and sanitation program across production and farm,
• Trained staff on personal hygiene and improved total concept of safety and hygiene
• Upgraded the pest control program to I.P.M “Integrate Pest Management” concept.
• Published the quality manual for Veterinary Microbiology & Serology and Plant Diseases.
• Published feeding organic and in-organic fertilizer testing method manual.
• Published the agriculture manual including the best practice for all fields.
• Controlled and executed new standard for receiving and use of nutrients and pesticides.
• Renovated of cream & cheddar cheese Jar recipe to meet market challenge with bench market.
• Improved Laban taste profile and gain 8% market share.
• Implemented N.P.D program, to improve performance. • Developed special Feta Cheese recipe in TP pack to meet market challenge with bench market.
• Innovated breakfast Cream recipe for catering and bakery usage.
• Improved fresh milk shelf life and reduced market return by 4.7%.
• Lead and manage the project from civil work activity up to equipment’s instillation, and prepared the start-up products recipe.
• Structured a newly found company from blank, and work out with stock holder for brand names and design.
• setup all production requirements, such as ingredients data per packs, B.O.M, S.O.P, CCP, raw and packing materials specifications
Achievements:
• Aided project sponsor in defining the project scope and benefits, and Implemented job descriptions, KPI’s and H.R requirements.
• Improved and organized the coming shipments and reduced transportation cost by 19%.
• Reduced the foreign welder cost by 34% by hire a local qualified welder.
• Setup pre-design and scope of work for W/H’s, cold stores, quotation for the required assistance system (e.g.: R.O Station, Water Treatment, Waste Water Treatment Station, and Doors….etc.).
• Re-designed the drainage system, according to dairy industrial standard, and designed Q.C, Q.A and R&D lab.
• Prepared development plan for the coming 3 years products.
• Lead and direct the quality and development teams, and restructured the team according to qualification and experiences.
• Maintained product quality by surveillance audits and investigating customer complaints.
• Implement and execute B.O.M system to improve product cost.
• Implement and executed the raw and packaging materials standard and ingredients specifications.
• Validated quality processes by established product specifications and determining operational and performance qualification.
Achievements:
I played a major role in reaching break-even by:
• Save 3.5 L.E Million/year on packaging materials by replacing the milk bottle sorting system with sampling plan system.
• Save 4.5 L.E Million/year by introducing grade B milk • Save 2.75 L.E Million/year by changed C.I.P Time & Percentage
• Save 800, 000 L.E/year by reducing defective product bottles from 1-3:100 to 1:100000, by changing aluminum lid type.
• Initiated and implemented the I.P.C \{In Process Control\} team with processing monitoring check list per product.
• Reduced bottle wastage levels from 1:1000 to 1:100000 by controlling and monitoring the blow-molding department.
• Reduced market complaints from 1:100 to 1:10000 using correction and preventive action system.
• Initiated microbiology identification program for monitoring UHT products, and improved NCR to 1/month.
• Published manual for control and monitor water treatment, boilers water and Industrial Waste Station.
• Certified the company for ISO9001, HACCP and ISO14001 year 2007 and ISO22000 in 2008, and prepared company for ISO18001.
• I initiated QMS section and Launch T.P.M, KPI”s and 5S programs.
• Executed T.Q.M to prepare the company for Quality National Awards for Excellence.
• Reduced the cost of products to meet the market challenge by 13%, by standardized the raw ingredients.
• Innovated Cherry fruit layered yogurt recipe, and full range of Milk & Juices recipes for exporting,
• Innovated a new range of 100% natural juice, improved Nectar juice range taste, and design Grape juice recipe,
• Reduced the cost of cheeses recipe by 24%, to meet the market challenge.
• Designed and executed new Recombining Milk, several types \{25%, 50%, 75% & 100% S.M.P\} for exporting market challenge.
• Lead and manage the quality and development department.
• Updated the quality manual, calibration, finished products, ingredients specification, S.O.P, raw and packaging materials standard.
• Initiated and executed B.O.M for controlling the cost effectiveness. • Prepared the company for ISO 14001.
• Improved pest control and hygiene methodology. • Insured ISO-9001 & HACCP updated to current.
Achievements:
• For the first time in KSA, in our department we employed women to work in the dairy lab field.
• Initiated and executed audit program on the restaurant, accommodations, food service suppliers and personal hygiene.
• Reduced products cost by reducing development wastage control of raw milk by 3%, raw and packaging material wastage by 7%.
• Published control manual for water treatment (Raw, Sweet and Juice Water), boiler water and industrial waste station.
• Publish quality manual for herd lab include: Feeding Analysis, Blood tests, Anti Biotic tests, Abortion, Aflatoxin, Mastitis & Soil testes.
• Initiated and executed microorganisms (Virus, Yeast and Mold) identification system, and introduced PCR technology.
• Initiated and executed G.M.P, G.L.P and O.E.E across the company business functional.
• Innovated and launched probiotics fermented milk called Raha and UHT milk for pregnant women called Mama’s Love.
• Designed several recipes such as Tomato, Milk/Juice & Vegetables Juice, vitality and energy drinks for 3 year production plan.
• Designed with co-packer several products such as Tri angle, Feta, processed Cream & Cheddar cheese and butter.
• Consultant for a newly found company, supported in defining the project scope, benefits & objectives.
• Setup chemical and bacteriology tests, R&D Lab equipment’s, raw and packing material specifications and recipes ingredients text.
Achievements:
• Work out with stock holder for brand names and design
• Define and assist on designing factory layout & blueprint.
• Workout with authorities to get license approval.
• Verified all equipment in France, and visited several cheese companies
• Lead and manage the night shift operation, implemented G.M.P and G.H.P principle, standardized the non-useable Potato.
achievements:
• Improved and reduced C.C.P by 50% • Improve hand packer speed to reach 4 boxes instead of 3.
• Broke the production quantity record against other shifts. • Setup a correction heat temp table according to potato types.
• Awarded Certificate of Merit for 100% attendance for 1 year 01/10/1998 to 30/09/1999.
• Lead and manage shift operation, and improved the KPI’s by after setup target for each one and reviewed in monthly basis.
Achievements:
• Reduced processing losses 1.5% and filling area 0.8% and saving 18 tons/month.
• Reduced C.C.P points by 32%.
• Work out with maintenance and implemented the preventive maintenance all over the site.
• Lead and direct the operation of Ice Cream factory including processing, filling, storage cold store, raw and packing materials W/H’s.
• Improved the performances across the functional, to launch the company strategy and five year plan.
Achievement:
• Evaluated staff to improve skills weaknesses.
• Initiated and executed a performance appraisal system to boost worker performance
• Implemented and executed GMP & GHP.
• Modified recipes to reduce biscuit cones cost by 18%.
• Enhanced the optimum speed for filling machines and continuous freezers to maximum efficiency.
• Reduced machine break time from 12% to 2.4% by introducing the preventive maintenance program; and implemented daily maintenance schedule for continuous freezers by production staff, and reduced un-managed stops by 11%.
• Reduced the wastage in processing from 3.5% to 1%, filling from 4.3% to 0.7% and packaging from 5.5% to 1% by fixing standard, monitoring, record, set-up C.P & C.C.P points, executed best practices concept, correction and preventive action plan.
• Initiated and executed S.O.P, policy and procedures, cleaning manual and training programs for second staff around work functional.
• I helped a mute worker become best operator earning him the “Nestle nest silver plate” award.
• Assisted in extending Nestle business across Egypt by preparing several opportunity studies, and gain one big business.
• Kick off with Nestle T.P.M group the Improvement Efficiency Program and reduced documentation handling by 34%.
• Lead and finalized special project of The Actual Cost of Raw Milk, and The Availability Quantity of Clean Raw Milk in Egypt.
• Modified packaging size for stick products to reduce total weight by 0.2 gram which lead to saving 6 tons / month of packing paper.
• Innovated new category of premium Ice Cream, and reduced water ice product cost by 18% and buffalo’s milk Nestle yogurt.
• Reduced cartons size and product number per carton to help marketing to open class C shops and its increased sales by 21%.
• Lead and manage the operation of producing vegetable ghee, butter, margarine and pastry margarine, bakery compound, Hydrogenated Vegetables Oil Ghee and Natural Ghee.
• Structured a newly found department, help and manage the requirements to install the production plant.
Achievements:
• Developed two formulas of Vegetable Oil Ghee for winter and summer time which reduced cost by 7%.
• Reached 1200 tons/week instead of 400 tons/week by adjusting machine speed, and training staff in handling machine speed.
• Developed a special formula for Pastry Margarine to be use in bakery across hotels.
• First stage: Construction, instillation and commission, help and support in all needs according to the project time tables. Help and assist in all activates starting from civil work, receiving equipment’s shipments, fixating lines with D.T.D and T.P Company, commissions, save foreign hand worker cost, by introduce qualified local worker and supervisors.
• Second stage: Starting and running the production lines, with prepared quality and R&D control system
Achievements:
• Initiated and executed the quality strategy, quality and recipes manual.
• Implemented release criteria for finished products.
• Initiated and executed SOP, W/H’s and loading standard.
• Implemented raw and packaging materials specifications.
• Implemented a test and taste system for flavors.
• Setup quality release system for UHT & fresh products.
• Reduced the cost of fermented cultures (approx. 24%) by introducing mother starter.
• Innovated a new range of Fruit Set Yogurt.
• Innovated a new category of juice with milk which saved 4.7% added sucrose.
• designed low price Fruit drink in cups,
• launch apricot nectar for Ramadan month once per year.
• Developed several new products such as U.H.T Guava & Mango milk, Feta Cheese, yogurt plain 5% Fat and stirred mixed fruit yogurt, Cheese (soft & hard), fresh and sour cream, Drinks, Nectar and Ice Cream variety.
Master Study joined with Nestle company, for real industrial experimental, spent 2 years studied materials related to food science, and 2 years test and experimental with writing my book, examined in front of 4 doctors in different field such as microbiology, chemicals, dairy and beverage, in the end I got my master degree 100%.
I studied for four years food science and related program, at the year of graduation my research subject was in microbiology of fermentation and starter used in dairy, I represented in English language, in front of committee from dairy department, and I got excellent grade with 98 out of 100, with recommendation to work with Milky Land Company, and its my first company I worked with in my career.