Operations Manager
Obeikan Investment Group
Total years of experience :18 years, 7 Months
Reporting to the Baseness Unit general Manager. Managing the BU supply chain and manufacturing operations with total headcount of 61 employees consisting of (2 managers, 5 E&T’s, 32 permanent technicians and 22 temporary employees).
• Managing HS&E plans and procedures execution through identifying and analysing the safety risks on people, assets and environment. (Implementing HIRA, PPE compliance).
• Managing quality in terms of first and second moment of truth by developing quality matrix and implementing machines centre-line system to minimize variation.
• Owning manufacturing OEE target and reducing unplanned DT and reducing waste (7% OEE improvement in Q1).
• Owning total delivered cost (TDC) of the finished product and develop cost saving plans through productivity optimization and raw material savings (examples: flow to work teams reduced OT by 10%, in house material customization delivered 50% saving and ZERO NPI on welding film )
• Owning manufacturing RCCP (rough cut capacity planning) and increase the capacity utilization by 25% in Q1 by implementing Theory of Constraint (TOC).
• Owning the implementation of TPM program by developing machines life-tables and time based maintenance schedules and track the execution adherence.
• Owning continuous improvement of the total manufacturing and supply chain by implementing PDCA cycle on daily, weekly and monthly basis.
• Organization development and optimization by implementing OPM tool (Organization Performance Model)
Acting as center of expertise for the lean manufacturing program and lead the implementation across the investment group (2 Packaging JV plants, 3 paper and board plants, 2 plastic plants, and 1 glass plant).
Main Achievements:
• Working with a 3rd party consultant to define the scope and develop the program maturity levels.
• Owning the TPM pillars program deployment with identified KPI’s and OPI’s.
• Owning OEE analysis and glide path development process across the group.
• Leading monthly TPM pillars health checks, gap analysis and action plans with the BU’s leadership.
• Companies were able to develop clear plans for OEE improvement and cost reduction as a result of deploying and implementing lean manufacturing tools.
• Monthly production records in August 2013 and October 2013.
• 15% productivity improvement in Downy Team through flow to work methodology.
• 10% capacity increase with Zero capital investment
• Successful launch of producing 2 new sizes on Downy.
• Successful launch of producing new formula in Downy with 1.5MM$ saving per year.
• Reducing the Changeover time on Fairy Lines by 50% through elimination of non-value added tasks.
• 15% productivity improvements through people capability development to build operate and maintain teams to run both Fairy and Downy lines and handle maintenance activities.
• Successful start-up (ISU) of new high production line for Fairy with >250 bottle/min with the available resources without having a dedicated start-up team.
• Delivering and sustaining Zero ppm in the SQM survey for 2014 for Fairy products.
• Established the loss analysis program with total opportunity of 45 million dollars.
• Established road map to recover 35 million dollars from the total loss opportunity.
• Deployed PR Hoshin analysis tool and built 3 years PR glide path to reach 85%.
• Improved the total packing lines MTBF from 30 min to reach > 60 min.
• Eliminated quality defects on liquids production line which resulted to annual savings of $125, 000.
• Reduced the brand changeover time on liquids production line from 35 min to 9 min resulting to annual savings of $100, 000.
•Tracking the Operational Performance Indicators such like, Equipment efficiency and Material Utilization for both Process and Filling divisions .
•Being exposed to the Quality Assurance standards and HACCP.
•Completing the graduation requirements to get the Bachelor Degree.
•Being exposed to the cementing lab equipment, tests and standards.
•Being exposed to the cementing equipment such that the Coiled Tubing Units, Quadric Pumps and the Blow Out Preventers (BOP’s).
* Major: Mechanical Engineering with focus on Mechatronics. *Graduation Project: Automaited Dentestry Excavator Tool . *Cumulative average: 68.3 % *Grade: "good"