Kamal Jamal

Senior Production & Operations Engineer | K-FLEX Group - Egypt | Jan 2025 - Present
-Lead operations of 8 production lines manufacturing elastomeric insulation products including tubes, sheets, and thermal insulation solutions for HVAC, plumbing, and industrial applications.

- Manage and supervise more than 200 operators and technicians across rotational shifts with strong hands-on involvement in daily production activities, machine setup, troubleshooting, process optimization, and shop-floor operations.
-Receive, install, commission, and ramp up new production lines imported from Poland, Italy, and Mexico while leading operator training programs, developing Skill Matrix systems, and evaluating workforce competency and performance.
- Monitor KPIs, OEE, and Pareto analysis while driving continuous improvement initiatives to reduce scrap, improve productivity, optimize manpower utilization, and enhance operational efficiency.
-Implement Poka-Yoke systems, lead SMED activities, prepare SOPs and Work Instructions, and support production planning, BOM creation, routing, and ERP operational integration.
- Support, prepare, and follow up internal and external audits including ISO 9001, UL Solutions, and FM Approvals audits while ensuring full shop-floor compliance with quality, safety, and operational standards.

Senior Production & Operations Engineer | ACROW MISR - ACROW Building Products | Jan 2024 - jan 2025
• Led production engineers, supervisors, and technicians across 3 PVC Foam Board production lines, overseeing end-to-end manufacturing operations and daily production performance
.• Managed production planning, manpower allocation, and process control for PVC Foam Board manufacturing while ensuring achievement of quality, productivity, and delivery targets.
• Drove continuous improvement initiatives through Kaizen, SMED activities, 5S implementation, and daily production analytics, resulting in significant operational performance improvements.
• Utilized daily KPIs, production statistics, and root cause analysis to optimize processes, reduce waste, and increase factory output from 200 boards/day to more than 600 boards/day within 12 months.
• Coordinated closely with maintenance, quality, and technical teams to maximize equipment availability, improve product quality, and ensure smooth plant operations.
• Developed strong expertise in PVC extrusion technology, PVC Foam Board production processes, line commissioning, troubleshooting, and manufacturing optimization.

-operating all machines in all factories ( changeover - molds installation ) hands on)
-achieving the production plan & allocating day to day manpower on different
function on production lines.
-direct production process per line and prepare production schedules
-monitoring scrap rate and the main reason of it and try to finish it from its root
-coordinates with the maintenance dep. The schedule maintenances without
disrupting production targets
-lead more than 500 manpower through the rotational shifts.