Mahmoud Samir

• Head of Manufacturing with over 11 years of expertise in the home appliance sector, adept at transitioning to roles such as Production Manager, Section Manager, and Manufacturing Manager.
• Proven ability to drive operational excellence and optimize resource utilization, ensuring seamless production workflows.
• Skilled in implementing process improvements that enhance productivity and reduce costs while upholding stringent quality standards.
• Recognized for strong leadership capabilities, fostering cross-functional collaboration to achieve high-performance outcomes.
• Excellent problem-solving and multi-tasking skills, consistently delivering measurable results in dynamic environments.
• Committed to continuous improvement and operational efficiency in manufacturing settings.

• Lead end-to-end manufacturing operations across Thermoforming, Metal Parts Forming, Tube Forming, and
General Components Assembly in a high-volume refrigerator manufacturing plant with an annual production
capacity of 400, 000 units. Accountable for achieving safety, quality, delivery, and cost (SQDC) targets.
• Direct a workforce of 250+ employees, including engineers, supervisors, and technicians, ensuring safe,
efficient, and high-quality manufacturing operations.
• Develop and execute production strategies aligned with business objectives, factory budgets, and customer
demand.
• Increased overall productivity by 20% through process optimization, capacity planning, and strategic resource
allocation.
• Reduced machine downtime by 25% by implementing preventive maintenance strategies and improving
equipment reliability.
• Prepare, manage, and monitor the annual CAPEX budget, evaluating investment opportunities to expand
production capacity, increase automation, and improve operational efficiency.
• Lead quality and continuous improvement initiatives using Lean Manufacturing, Six Sigma, Root Cause
Analysis, and Kaizen methodologies.
• Develop manufacturing KPIs and monitor productivity, OEE, downtime, quality performance, and production
efficiency to support data-driven decision-making.
• Design employee performance evaluation and technical training systems to strengthen workforce capability
and leadership development.
• Ensure full compliance with health, safety, and environmental regulations across all departments.
• Recognized twice with the Best Continuous Improvement Project Award across Elaraby Group manufacturing
plants for leading high-impact engineering and continuous improvement projects that delivered more than
USD 1 million in CAPEX savings while significantly improving productivity and operational performance.

Section Manager - Metal Parts Forming Presses (Refrigerator Sharp Factory) Led the metal forming presses section, driving process efficiency, product quality, and equipment reliability through proactive planning and performance monitoring.

• Reduced defect rate by 70% through root-cause analysis and strict process control.
• Increased OEE by 15% by optimizing operations and minimizing downtime.
• Extended die life by 10% with preventive maintenance and optimized usage practices.
• Reduced changeover time to under 10 minutes, boosting flexibility and throughput.
• Defined and monitored performance indicators and process outputs, ensuring corrective actions for
deviations.
• Enforced detailed application of operating instructions at every step to meet product specifications.
• Developed and executed maintenance plans for dies, templates, and production tools, validating new
components through initial testing.
• Collaborated with the Maintenance Department to implement machine maintenance schedules, reducing
breakdowns and improving efficiency.
• Monitored daily production trends, analyzed variances, and applied corrective actions to sustain high-quality
standards.

• Managed Metal Parts Forming Department (70 employees, including engineering and Tool & Die teams),
overseeing progressive stamping, shutle press, tapping, riveting, and welding operations.
• Reduced production defect rates by 70% utilizing Root Cause Analysis (RCA) and strict process controls.
• Implemented SMED methodology, successfully reducing changeover times to under 10 minutes to enhance
production flexibility.
• Led cross-functional continuous improvement initiatives with Quality, Maintenance, and Supply Chain to
optimize throughput and ensure on-time delivery.
• Executed more than 30 Kaizen projects focused on minimizing normal scrap rates, achieving 25 % reduction in
material waste costs.

Engineer & Section Manager - Thermoforming (Sharp Refrigerator Factory) Managed thermoforming operations with a focus on capacity planning, continuous improvement, and equipment reliability to support production growth and quality excellence.
Key Achievements & Responsibilities:
•
Participated in the installation and commissioning of a new thermoforming machine, ensuring smooth integration into operations.
•
Implemented multiple Kaizen initiatives to streamline processes, reduce costs, and improve efficiency.
•
Decreased COPQ (Cost of Poor Quality) by enhancing process controls and quality assurance measures.
•
Increased machine reliability through preventive maintenance and optimized usage practices.
•
Coordinated equipment repairs and maintenance to minimize downtime and sustain production continuity.

Managed thermoforming operations with a focus on capacity planning, continuous improvement, and equipment
reliability to support production growth and quality excellence.

• Led Kaizen initiatives within the thermoforming process, enhancing cycle times and reducing Cost of Poor
Quality (COPQ).
• Optimized machine reliability and operational uptime through enhanced maintenance coordination.
• Collaborated on continuous improvement projects to streamline material usage and reduce sheet thickness
variation defects.
• Applied 5S principles and optimized department layout to improve workflow.