Production Dircetor
Sudair Company for Manufcaturing
مجموع سنوات الخبرة :11 years, 11 أشهر
• Leading a team of 350+ people and reporting to CEO.
• Managing the OpEx budget of USD 3.0 Mn and capital budget based on a business plan.
• Leading Manufacturing, Maintenance, Supply Chain, New product development/improvement, New Projects, Continuous Improvement, and OpEx/CapEx budgeting.
• Revamped production processes by mapping out value stream maps (VSM) resulting in an 85% increase in productivity and a reduction of 30% in lead time.
• Developed and implemented an advanced quality assurance program that resulted in a 55% decrease in rework costs, saving the company $200K annually.
• Collaborated with cross-functional teams to streamline communication channels, enabling the company to reduce production cost by 40%, leading to $1.3M in savings annually.
• Developed and implemented the advanced machine maintenance system resulting in a 50% reduction in downtime.
• Identification of Key Areas for improvement in line with the client’s business strategy and assist in prioritizing projects based on business needs.
• Training/facilitating/guiding all employees at all levels on Lean and Problem-Solving tools.
• Formation of cross-functional teams as per project need.
• Periodic onsite/off-site reviews with teams and assist the Steering Committee for reviews.
• Led teams in 4 countries Kenya, Tanzania, Uganda, and Mozambique, and reported to Group CEO.
• Improve the working efficiency by improving process flow, reducing the production cycle time by more than 50% through Value Stream Mapping.
• Developed and implemented the advanced machine maintenance system resulting in a 60% reduction in downtime machines and vehicles.
• Improve the sales by 20 % through improving OTIF (On Time In-Full) delivery and reduced the Finished Goods inventory by 30% using the JIT concept.
• Set up the “KANBAN” system, decreased inventory by 30% of fast-moving products in 6 months, and improved the availability of other products to reduce sales loss.
• Introduced Just-in-Time (JIT) to reduce stock-outs by 80% in 6 months, eliminating sales loss of US$ 350k/month.
• Led the company to win the National Level Business Excellence Awards (COYA)
A Deming organization and a joint venture with SUZUKI and JTEKT (a subsidiary of TOYOTA) and largest manufacturer of Steering Systems in India. This is also a Tier 1 Auto OEM Supplier supplying to all Auto OEMs like Suzuki, Toyota, Hyundai, Tata Motors, Ford, General Motors and Mahindra.
• Developed and implemented an advanced Quality System (Continuous Improvement) to drive Quality Culture and ensure implementation of initiatives across 3 plants.
• Implemented statistical process control (SPC) methodology resulting in a 45% reduction in variation and a 25% improvement in defect detection accuracy.
• Developed 250 QC Circles (Team-based problem solving) across the organization to promote a “Continuous Improvement” culture and implemented 16 projects for productivity improvement from 25% to 40% in different lines.
• Implemented training programs for employees on lean manufacturing, resulting in 30 projects on Warranty Reduction, Customers Returns, Internal Rejection, and product improvement.
• Planned, designed, and coordinated the development of Knowledge Management Systems to create the knowledge depository for future reference.
• Developed an internal audit mechanism for the Quality Systems initiative and conduct internal audits to ensure the effectiveness of implementation resulting in achieving the JIPM-TPM Excellence Award.