Plant and Operation Director
Pure Beverages Industry Co.
Total des années d'expérience :13 years, 10 Mois
Manage the complete Manufacturing and Supply chain activities for Mega Plant in Riyadh & Jeddah with 6 Krones high-speed production with a yearly output of 2.8 billion bottles with over +200 employees, with full responsibility for P&L ensuring that plant is managed, maintained, and operating at world-class standards. Coordinate and direct the quality management in line with the QA system, FSSC22000, and ISO 9000 procedures and ensure compliance with SOP’s and HACCP programs. Originate and enforce occupational safety and health procedures to guarantee the safe execution of all Operational activities including inventory management, maintenance, and, participating in the business planning and budgeting process by developing short and long-term cost strategies and tactics.
• Deployed and managed to deliver the annual operation plan and financial results including targets on service, costs, productivity, efficiency, quality, and HSE
• Pursue a site long-term plan, including restructuring, re-engineering, and retrofitting, prioritize and plan resources development and deployment
• Engage and facilitate the implementation of innovations on-site, for new product development, ways of working, service models, and supply chain models
• Lead Several Lean Manufacturing Projects to improve line changeover, CIP frequencies, line start-up, Packaging optimization, trucks optimization, and Wastage with saving more than 20 million SAR
• Stewardship environment & sustainability initiative by conserving WUR & EUR through six sigma projects lead to green impact and direct cost saving by 4% vs budget
• Innovated, Industrialised, and tailored the Pure Beverage Continuous Excellence (PBCE) program.
• Lead the first retrofit speed upgrade project in the MENA Region for five lines with the Krones team and successfully increase the lines’ speed from 81K bph to 84K bph with +3% Output
• Lead an expansion project with +15, 000 m2 including civil work and machinery with 45 million SAR
• Lead the factory preparation and accreditation from AIB (American Institute of Bakery) and NSF (American National Sanitation Foundation) and IBWA (International Bottled Water Association)
Strategize, unify, and oversee the manufacturing process with +75 employees & 7 Production lines to enforce a positive return on P&L. Lead initiative and operation plans to reduce manufacturing costs inclusive of direct material usage variance. Conserve the efficiency of production lines and maintain capacity utilization. Plan for capital projects comprising equipment, machines, processes, and infrastructure. Authorize team recruiting & training requirements. Observe expenditure and control the budget for Plant and key projects. Devise and submit monthly reports for senior management. Originate and enforce occupational safety and health procedures to guarantee the safe execution of all plant activities. Maintain the facility and assets in line with regulatory guidelines and ISO, OSHA, and FSSC standards.
• Innovated, Industrialized, and directed the Agthia Continuous Excellence (ACE) program.
• Lead the delivery of the Operational Excellence framework for manufacturing.
• Reduced manufacturing overhead (MOH) costs by 15% via the optimization of the energy and
water usage ratio and improved Overall Equipment Effectiveness (OEE) by 5%.
• Improved Production plan adherence by 5%, optimizing shift schedule along with OT reduction
by 12%
• Established good manufacturing practice (GMP) with a 95% score throughout the plant to
ensure that products are consistently produced and controlled according to quality standards
• Building a culture of development and inclusion, to retain talent and develop a robust
succession plan throughout the organization.
• Analyzing production and operating reports and resolving operational, manufacturing, and
maintenance malfunctions ensuring minimum costs and preventing operational delays.
• Delivery of the budgeted targets and effective achievement of the manufacturing KPI’s
Reconstructed, developed, and reshaped the engineering process and team to enforce a positive return on assets. Lead initiatives and Maintenance plans to reduce Maintenance costs by Conserving the efficiency of production lines. Lead capital projects Planning & Execution for the plant improving equipment, machines, and infrastructure. Partner with planning and procurement teams to enable effective risk and project management. Authorize team training requirements. Observe expenditure and control the budget for maintenance and key projects. Originate and enforce occupational safety and health procedures to guarantee the safe execution of all Operational activities. Concoct and update technical knowledge, SOPs, and procedures. Coach the Lean Six Sigma community, comprising 2 teams. Steer six sigma projects and uphold operational excellence.
• Fronted a successful project for the installation of a new production with 81, 000 BPH line
including all machines and utilities with greenfield land, valued at 60M SAR in line with time
frames and agreed acceptance criteria.
• Led a short neck conversion project for the PET line and secured an annual saving of 1.5M SAR.
• Restructured the maintenance team and reduced 40% of the non-essential headcount.
• Headed up the implementation of Total Productive Maintenance (TPM) program & re-design
the Preventive Maintenance Program
• Ensuring proper maintenance of all production machinery by coordinating these functions as
necessary with the Facilities/Maintenance team & increase overall line Efficiency (USLE) by 6%.
• Slashed maintenance costs by 30% and reduced the stock value of the spare parts by 20%.
Industrialized and applied the maintenance and project strategy across the factory. Governed capital projects. Guaranteed adherence to health and safety legislation. Monitored, controlled, and reported on daily operations. Assured the implementation of Nestle Continued excellence (NCE) in all processes. Mentored and developed the team to craft a diverse team of high-performing associates. Administered stock control and tracked and managed the inventory. Shaped and enforced maintenance schedules. Ran yearly factory overhauling.
•Instigated the implementation of the Nestle TPM program which reduced BD by 4%.
•Facilitated the Audit committee for the factory in Saudi Arabia which resulted in a successful audit pass without any critical or major findings.
•Orchestrated a six-sigma project pertaining to Energy Savings to inspire an annual saving of circa $15K in water and electricity costs.
• Implemented a Certified Lean Black Belt Project with Symbios Consulting for Improving Maintenance and Equipment Management module for HOD Business
•Commanded a project to advance the HOD business which enhanced annual profit by circa $300K.
•Guided the Nestle Continuous Excellence (NCE) Program to enable process improvements by acting as Champion Leader for Focused Improvement Pillar
•Dramatically increased PM Compliance (preventive Maintenance) to over 85%
•Reduced line change-over & frequencies by 30% by applying 3 SMED projects
•Led several Kaizen, 5S project and continuous improvement workshops
Employed SAP to plan and schedule preventive maintenance. Executed the capital projects plan, and scrutinized the maintenance budget, contracts, and costs. Directed maintenance overhauling and annual plant shutdown works for machinery and equipment. Spearheaded capital projects and fashioned site master plan activities relating to operations, machinery, and equipment. Managed the spare parts inventory, reordered stock to maintain adequate levels, and upheld SOP's. Purchased spare parts and R&M services.
•Shepherded the enactment of the Coca-Cola Operational Excellence program.
•Headed up the implementation of the Coca-Cola Atlantic EXIM Program (Excellence in Maintenance) which resulted in a 5% increase in efficiency improvement.
•Utilised SAP to effectively implement the CMMS Program for maintenance and spare parts which comprised both plant maintenance and material management modules.
•Mastered Root Cause Analysis methods and techniques to eliminate machine potential failure
•Piloted a six-sigma project to cut production material (MUV) costs and secured a yearly saving of $21K.
•Managed to deliver Projects for new machinery and equipment with the value of $2.5M that improve automation level in the factory.
•Implemented an EMS (energy management system) project to live monitor and report energy usage and improvement initiatives
•Guided the implementation of BBS (behavior-based safety) for the factory team
•Led 5 Process Improvement Projects in production, maintenance & Warehouse
Effected production plans. Used Oracle EAM to perform scheduled preventive maintenance. Responded to breakdowns, diagnosed faults, and repair equipment. Supervised operation technicians and technical staff. Conserved statistical and financial records for production plan compliance and material wastage. Inspired the application of the Coca-Cola Operational Excellence Program. Ensured ongoing compliance with health and safety legislation.
• Supervised Production line installation and commissioning.
• Reported Production Line Utilization, Productivity, and efficiency.
• Tackled Raw Material Yield, Wastage, and Production Plan Adherence
• Prepared & supervised two successful Overhauling for Krones production Lines
• Designed & Launched Plant Maintenance module, BOM & Routing for Maintenance activities
• Electrical & Mechanical training in Krones academy in Germany for (Pasteurizer, Blowing, Filler, Cooler, Labeller, Variopac, and Palletizer) including process, operation, and maintenance for specified machines.
• Food Safety team member responsible for HACCP Analysis & GMP Application.
ESLSCA PARIS UNIVERSITY
Accredit from EDI (Educational Development Institute) & LCCI (London Chamber of Commerce and Industry International Qualifications), License Serial No. 21455519 - F035152
5 years of studying Electrical engineering
