Factory Manager
Universal Group For Home Appliances *** (An Egyptian market leader in household appliances)
مجموع سنوات الخبرة :27 years, 11 أشهر
(Reporting to the group managing Director)
Develop, implement and review suitable short and long term plans to achieve assigned Plant and group objectives such as the profit plan, strategic plan, human resource organizational capability plan and forecasts.
Plan, organize and direct the manufacturing and maintenance operations which ensure the most effective return on assets.
Provide leadership, direction and manage all Plant operations to include manufacturing, operational excellence, material, quality, HSE and human resources.
Initiate plans and processes which minimize manufacturing costs through effective utilization of manpower, equipment, facilities, material, and capital.
Assure attainment of business objectives and productions schedules while insuring product standards.
Implement manufacturing strategies and action plans to ensure that the facility supports the corporate strategic initiatives.
Establish group and individual accountabilities throughout assigned departments for problem solving and cost reduction.
Encourage use of new techniques and focus on fact based problem solving.
Improve manpower utilization within existing departments and processes.
Monitor spending against budget and in relation to changes in production volume.
Establish management practices throughout assigned areas which include all employees’ positive involvement with opportunity for construction input and action.
Continually improve safety record by addressing both physical safety issues and employee safety attitudes.
Maintain individual skills keeping up to date with latest production and production management concepts.
Coordinate and direct through managers, all functions of facility operations, including but not limited to manufacturing, asset utilization, inventory control, facilities control, building lay-out and construction, maintenance, manufacturing projects and studies, cost control, manpower utilization, work standards and administration.
Responsible for contributing to the development of all plant policies, consistent with the direction of the overall Universal organization
Implementation and adherence to the corporate Business Operating System.
Create an environment of employee engagement by embracing continuous improvement culture tools.
Ensure compliance with all government, environmental and labor regulations.
Project manager for corporate development project in Universal with the managing director under umbrella of European experience house (P&P design-Italy).
Develops and maintains innovative and effective cost reduction programs throughout operations.
Provides leadership and commitment in support of continuing improvements in quality, productivity and delivery performance.
Assessing monthly performance reports as per company norms.
Key Contributions:
Mange the newest plant project in Universal group from scratch till running within 14 months.
Successful implementation of cost saving projects for about5M EGP yearly compared with the older plants
Successful implementation of Universal development project till now +30% in productivity achieved.
Achieved 100% APO (Annual Performance Objectives).
Ability and balancing between the plant management and development project with Italian experience house through the other plants in the group.
(Reporting to the General Manager)
Plan, organize and lead the operation team to achieve the agreed objectives.
Ensure adherence to all Company principles and policies as well as local laws and regulations.
Ensure compliance to health, food safety and regulatory requirements of all products manufactured.
Ensure development of the operation team and staff - through performance management, career development, succession planning and coaching.
Collaborate with peer factory managers to share best practices.
Ensure smooth operations by effectively managing Employee and Industrial Relations. Build and maintain positive community relations
Ensure the full implementation of all aspects related to the operation Dept.
Implement TPM on all lines according to a structured and agreed plan by the Business and Technical Manager.
Key Contributions:
Participation in food safety management ISO22000, implementation & certification.
Motivating staff& increasing people productivity by 25% by designing tailored incentive plans.
Cost saving about 5% in the raw material, and 15% in Polypropylene labels.
Successfully designed a work in Progress (WIP) transaction database.
Achieved 100% APO (Annual Performance Objectives).
(Reporting to the CEO)
Responsible for the technology know-how management. Assisting factory for trouble-shooting of any technical issues with regard to new or existing products. And assisting in supplier management in collaboration with other parties (e.g. supplier approval, audit).
Monitoring and review all Assets and Maintenance reports and main KPI regarding labors utilization, technical store, maintenance plans and costs are tracking in line with Guidelines
Planning, co-ordination and control of industrial processes.
Reporting to the CEO the production, quality, maintenance and production planning weekly reports.
Drawing up a production schedule.
Working out the human and materials resources needed.
Estimating how long a job will take, costing it, and setting the quality standards.
Monitoring the production processes and adjusting schedules as needed.
Key Contributions:
Managing Coca-Cola, PEPSI and NASTLE audit (Customer audit) twice and passing them successfully.
Reducing the turn over from 20 % to 3 % by rotation, upgrading, implementing salary Skelton, and adjusting the incentives policy with HR Dept.
Motivated staff & increased line productivity by 50 %.
Achieved 100% APO (Annual Performance Objectives).
Reducing the overtime cost by 75 %.
Successfully designed and reorganized the warehouses for a work in Progress (WIP), the result were reducing the abnormal scrap from 7 % to 1 %.
(Reporting to the Plant Manager-Washing Machines Plant)
Planning, co-ordination and control of industrial processes.
Reporting to the general manager the production report for every month.
Drawing up a production schedule.
Working out the human and materials resources needed.
Estimating how long a job will take, costing it, and setting the quality standards.
Monitoring the production processes and adjusting schedules as needed.
Supervising and motivating my team, span of control is 658 followers (8 Engineers and 650 workers, technicians and supervisors).
Training instructor for a heads and technicians of after sales service.
Preparation the products specifications for the production dept. for each client.
Searching and getting new clients from abroad.
Helping the production dept. to solve the technical complaints.
Following up the procedures of loading and shipping for orders.
Receiving clients' complaints, studying them with the technical dept. to solve them and preventing them in the future.
Managing all documents related with export dept.
As technical reference during the tryout period of news dies for new versions of gas cookers
Following up the production of W/M dept. . . .
Making the time study and line balance for production line and following up the production efficiency
Put the process sheet.
Solving the problems of bottle neck in the lines.
Put the plans for production & manpower skills improvement.
Creating the technical instructions for all equipment and machines in the W/M dept.
Organize and making training course on troubleshooting for all after sales service technicians.
Following up the quality assurance of W/Ms.
Additional tasks:
Calculate the values of loads and their distribution at new installations (lines and machines )
Calculate the requirement for these electrical loads from cables, panels' specification of the installations.
Follow up the execution of the new installation
Make purchasing orders
Discuss the offers with the suppliers
Reporting to the general manager my recommendation for the best offers.
Make the checklist and steps for the PM. Sheets of all Equipments (daily, weekly, monthly, semiannual and annual) Referring to the machine catalogues.
Re-organize the coding system of 15000 items for BAAN system
Making the routing and bill of material for W/M models.
Revision of the routing and bill of material for all depts. (manufactured parts and final products).
Design and construction of electrical panels that will be used for starting and control of the industrial systems (plants).
Manufacturing types of testing machines Responsibility for example:
1.DIGIT - PC is used as station of evacuation and charging of circuits and cooler systems.
2.HELICHECK: is used to check and looking for the leak in systems. Circuits, component under pressure and \ or depression) using spectrometer that use helium or air helium mixture as tracing gas)
3.VACUUM CONTROLLER is used for drying the circuits and components (Radiators, condensers of cooling systems… etc under vacuum.
Responsibility for electrical, mechanical and electronic maintenance of our plants or MC/S.
Installation of our machines and plants,
Setting of digital indicators which connected with PC.
Creation of relays package that will be used as interface between the industrial PC and mechanical, electrical loads.
NOTICE: contents of plants or M / CS are industrial PC, spectrometers, sensors of pressure, vacuum and temperature, digital indicators of pressure and vacuum, vacuum pumps, liquid pumps, testing champers, pistons, electrical and pneumatic vales, ventilating fans, and control panels which consists of PLC, C. Breaker, contactors, timers, transformers, power supply and transmitters, … etc
Supply, assembly, installation & connection of electrical equipments such as transformers, cables, boxes, circuit breakers, relays and timers required for power supply to industrial systems, factories, and buildings.
The Supply Chain Course included the following issues : 1) Introduction to Supply Chain Management 2) Demand Planning 3) Master Planning 4) Material Requirements planning 5) Capacity Management 6) Inventory Management 7) Logistics and Distribution 8) Customer Relationship Management 9) Supplier Relationship Management 10) Managing and Improving the Supply Chain
1. a) Conducted Subjects: Strategic management – Corporate governance – Operation and processes management – Accounting and finance – Globalization and Entrepreneurship – Strategic human resources – Succession planning – strategic Marketing – New product management– Performance management – Leadership, and Final project: manufacturing processes development and its impact on the company productivity at Everest Egypt company. 2) Awareness of OSHA 18001 4) Awareness of food safety 22000 5) Awareness of GNP and HAACP 6) Awareness and internal audit according to ISO 9001:2008 7) Awareness and internal audit according to ISO 18001:2007 8) Awareness and internal audit according to ISO 14001:2004 9) Microcontroller programming from faculty of engineering – Cairo University. 10) PCB Troubleshooting from SITCO Centre for education – Cairo.