R&D Director
Arab Dairy
Total years of experience :23 years, 5 Months
Job title; R&D Director, reporting to GM, Team 4 persons.
Research and Development | Role, Major Activities;
-Set the trials plans, Documentation, A/P's, NPD, Innovation, Coding Recipes, Shelf Life study, Monitoring of all activities related to R&D, Design, Specifications, Sensory Evaluation and Cost Control.
-R&D procedure, idea phases, innovations and NPD by methodology and methods.
-Set and manages R&D program and roadmap under the umbrella of the company's trends to meet organization needs and to capitalize on potential new products.
-Lead New Product Development Process from ideation to launch.
-Evaluate the requirements for new products based on the market needs, and work closely with marketing
-Follow up the new trends, by many ways in technology vs competitors.
- Submit periodical reports to top management showing the status of R&D progress.
-Communication and sharing strategies with companies as (CHR-Hansen, DSM, Arla, Danisco, Ingredion, Cargill, BK, Tetra-pak, Amcor... etc.), to value add innovations and materials.
-- Technical and quality files for all clients and requirements as private label;
Carrefour UAE https://www.carrefouruae.com/Default.aspx?language=ar, Unikai http://www.unikai.com/ Smeds international http://www.smedsinternational.com/,
Kalleh Dairy Co. www.kalleh-icecream.com LuLu Hypermarket Dubai http://www.luluhypermarket.com/AE/all
Research and Development | Achievement and Projects
-Number of projects 37, (35 as Team leader and 2 as Team member).
-33 Technicality projects and 4 “Process, Business, and others” projects.
-Contributing to 23% of business growth.
Processed Cheese | Glass Jar.
-Establish all recipes from “A to Z”.
-Adding new recipes “Smoke, Cream, Blue …etc.”
Processed Cheese | Blocks.
-Cost reduction recipes.
-Adding new recipes “Light, Shredded, Olive, Paprika…etc.”
-New Recipes to export clients with different requirements and specifications.
Processed Cheese | Triangles.
-Cost reduction recipes.
-Re-launch Panda with new recipe.
-Adding new recipes “Light, 55%, 45%, Parmesan, Blue…etc.”
-New recipe for GSO standard.
-New recipe for very low protein.
White Cheese | Tetra-Pak.
-Re-launch Panda with new recipe
-Adding new recipes for cost reduction and raw materials.
-Adding new flavors “Barmillii, Istanblii, etc.”
-New Recipes to export clients with different requirements and specifications.
White Cheese | Brine.
-Added new flavors Baramilli, Olive.
-Bake Stable Cream Cheese for filling bakery.
-New recipe “low salt, Talaga” and cost reduction.
Mozzarella Cheese
-New project cost saving and improvement quality product.
-Adding new recipe “Light Mozzarella analog”.
-Improving the shelf life for mozzarella keep in cooling.
-New Recipes to export clients with different requirements and specifications.
Innovation, New Product and New RM/PM
-New method to using fresh milk improve taste, texture and cost saving.
-Innovation project for White cheese to improve taste, texture and cost saving.
-Innovation raw materials for Mozzarella cheese improve taste, texture and cost saving.
-Innovation for Khazeen analogue and jalapeno.
-Thick cream, from A to Z.
-New recipe for Mesh analogue.
In process processed cheese slices, Kiri, Philadelphia types and healthy projects.
-Innovation Hard Cheese analogue.
-Re-using the returns.
-Creating White cheese Brine and TP with many kinds of pieces by development new stabilizer.
-Processed Cheese Casing; Establish from A to Z, adding new recipes “Olive, Paprika, Smoke …etc.”
-NPD of Mozzarella sticks breaded for local and export.
-Nondairy cheese as Tofu for triangles and blocks.
-Add new materials (stabilizers, ant-caking, preservatives…..etc.).
Job title; Business Development Manager, reporting to CEO.
Business Development | Role, Major Activities;
- Identifying, and developing business opportunities by maintaining strong relationships with existing clients and finding potential clients.
- Contribute to all discussions and decision making that relate to the organization’s strategic plans, assisting in maximizing revenue opportunities and profitability and put A /P.
- SWOT Analysis; work closely with marketing to build a company’s profile to increase market share.
- Developing partner commercial aimed at maximizing ROI and put KPIs.
- Feasibility Study for new product launches, inclusive pricing & product planning
Business Development | Achievement and Projects;
- Number of projects 14, (9 as Team leader and 5 as Team member).
- 8 Technicality projects and 6 “Process, Business and others” projects.
- Contributing to 18% of business growth.
Technicality
- Participating for the opening of new markets “Russia, Colombia, Venezuela, Philippines, Azerbaijan and Mauritius” increase the sales forecast.
- Increase the business volume of existing clients Lebanon, Iraq and Yemen.
- Re- active the local and export clients that stopped after resolve any issues.
Process, Business, Management, Administratively and others
- Adding new 26 SKU’s Tetra-pack, Mozzarella and Triangles to add value to our market export and local.
- Development the B2B for local market to increase business.
- Participating for decrease COG’s.
- Changing of breakeven for Triangles and white cheese brine.
- New deals for many tenders local and expor
Research and Development | Role, Major Activities;
- Set the trials plans, Documentation, A/P's, NPD, Innovation, Coding Recipes, Shelf Life study, Monitoring of all activities related to R&D, Design, Specifications, Sensory Evaluation and Cost Control.
- R&D procedure, idea phases, innovations and NPD by methodology and methods.
- Set and manages R&D program and roadmap under the umbrella of the company's trends to meet organization needs and to capitalize on potential new products.
- Lead New Product Development Process from ideation to launch.
- Evaluate the requirements for new products based on the market needs, and work closely with marketing
- Follow up the new trends, by many ways in technology vs competitors.
- Submit periodical reports to top management showing the status of R&D progress.
- Communication and sharing strategies with companies as (CHR-Hansen, DSM, Arla, Danisco, Ingredion, Cargill, BK, Tetra-pak, Amcor... etc.), to value add innovations and materials.
Job title; Lean Six Sigma Manager, reporting to CEO, Team 2 persons.
Lean and Six Sigma, Project management | Role, Major Activities;
- Identify priorities and opportunities in entire organization for improvements and execute operational excellence events.
- Coordinate with management, cross-functional team in execution of daily tasks and function as well as company strategic projects.
- Coordination of all activities relating to enhancing knowledge of using the tools and techniques of operational Excellence / Lean methods, Kaizen and 5S.
- Minimizing the variation of process and generate ideas for breakthrough strategies.
- Put the standards, targets, methods for targets and follow up.
- Applying project management methodologies.
- Performance cycle time reductions, plant layouts, scrap control and reduce waste & defects % cost control in the manufacturing process, bottlenecks’.
- Ensure that all senior management are aware of (BSC) through the delivery of effective training and establishing KPIs. Conduct self-assessment using the RADAR Scoring Matrix.
- System of ideas, participation HR in rehabilitation and training and re-evaluation.
- CAPAEX, Budget, capital outlay and any future investments and ROI, payback of projects.
- Manages continuous improvement programs, build trust, and create culture of innovation.
Lean and Six Sigma | Achievement and Projects;
- Number of projects 64, (24 as Team leader and 40 as Team member).
- Technicality 18 projects and “Process, Business, and others” 46 projects.
Technicality
- Inventory management project to reduce the stock.
- New packaging materials for mozzarella and blocks.
Process, Business, Management, Administratively and others
- 4 projects of Six Sigma “DMAIC “Processed and White cheese.
- Gab assessment study and set A/P’s for development company including (main problem, root cause, roadmap, KPI’s, performance, bottlenecks, utilization, manpower and wastes, SWOT, etc.).
- New filling for white cheese reduce manpower “35 workers.
- Spare parts and overhaul project.
- New strategy of suppliers, to avoid risks any shortage.
- New modification of machine, easy open Blocks with Aluminum.
- Deal for utilities cost reduction VS budget visit Holland, Germany.
- De-packaging (cost reduce the wastes of triangles).
- Re-use and utilization the stagnant.
- Aluminum foil project of triangles to cost saving.
- Add a new technique for solving problem, SIPOC system, PQCDSM, 7 waste, visual management.
- Improve the maintenance “preventive, emergency, predictive, performance and OEE”.
- Installation of sensors for machines “blocks and triangle “reduce wastes.
- Reengineering some areas to saving time, efforts and money with VSM”.
- Follow-up all initiatives and projects of company and lead projects “Supply Chain, Factories, sales…etc”.
- H&S; training, A/P’s, zero accident tolerance', safety line, fire alarm system.
- IT; implementation ERP system “warehouse, finance, sales, manufacturing”.
- Finance; Debt, smart budgets, CAPEX.
- HR; Job description, Job evaluation, Recruitment System Ideal Structure.
- Factory; productivity, capacity, utilization, new machine mozzarella analog, thermoforming machine, Boiler, Sheller, generator, recombining unit and Air compressor.
- Maintenance; install three Tetra-Pack machines, pasteurization, transfer some machines and overhead for seven machines.
Job title; Quality Manager, reporting to GM, Team 104 persons.
Career Development; Promote gradually from Head Section, Food Safety Manager, Q.C Manager, Q.A Manager then Quality Manager.
Quality and Food Safety | Role, Major Activities;
- Establish and implement departmental policies, targets, budget, KPI's, organization updated, Quality map, planning for QC activities and PDAC, sampling plans, SPC, testes, check list, Auditing, critical points, gap analysis, documentation system and ISO requirements’ and updated
- Minimizing the deviations and reduce the variation to ensure that all processes within limit, prepare quality reports and put A/Ps to improvement.
- Suppliers’ development program, work closely with supply chain for supplier approval.
- Create a culture of quality throughout every departments of company.
- Leads training program to educate employees on how to improve the quality.
- COAs release, update of QC along with new products and customer requirements.
- Manage food safety program “HACCP, GMP, Best practice, QMS, Hygiene plans”.
- Updated all spec's (finish product, raw materials and packaging), AQL, QDI.
- Execute all corporate food safety related strategies, policies and procedures; maintain open communication with all related departments to address the identification of food safety hazards and process improvement opportunities for Product Lifecycle and recall, traceability, calibration.
- Management Representative; investigation of returns, customer complaints, satisfaction, compliance, management review meeting, preventive actions and put A/P’s.
Quality and Food Safety | Achievement and Projects;
- Number of projects 22, (12 as Team leader and 10 as Team member).
- Technicality 8 projects and “Process, Business, and others” 14 projects.
- Contributing to 14% of business growth.
Technicality
- Establish Specs for finish products referred to Egyptian standards and Codex.
- Establish sampling plan according to military standard, AQL and QDI.
- Establish the technical specifications of packaging & raw materials and put testing methods.
- Auditing of dairy farms and development.
- Reviewing and issuing all SOPs, WI.
Process, Business, Management, Administratively and others
- Improvement the warehouse and follow up FIFO system.
- Developing the suppliers’ performance programs, and increase suppliers with supply chain to backup.
- Studying of Market competitors by in shop samples, and training for 54 sales team.
- Reducing the returns 1.9% in 9 months, and the customer complaints # from 35 to 14 in 8 months.
- Put the training program of 28 customers and Key account to reducing returns percentage.
- Machines assessment and improve its performance from 65 % to 85 %.
- Customer satisfaction and Follow up the key customers by analyses and A/P.
- Initiating the supplier evaluation system, Development 6 suppliers have safety issue.
- Set the program for internal audit & external audit and development record.
- Set and Start the big project of training programs to changing the culture included (GHP, GMP, SOP, ISO, HACCP, Statistic, Lean, and Six Sigma) within 3 years.
- Lead a training for 1200 employees (Hygiene, GMP and food safety).
- Investments and improve infrastructure.
- Increase the degree of GMP from 63% to 84% in 11 months.
- Reducing NCR 5%.
- Montana Company has been working in the field of food processing "manufacture various frozen vegetables - scale annual production 25000 tons of the number of employees working 550-Workers on the domestic market and export to the Arab countries, Europe and USA market leader in Egypt.
Production and Operations
Job title; Production Head Section, reporting to Operation Manager, Team 470 persons.
Career Development; Promote gradually from Production Engineer then Production Head Section.
Production and Operations | Role, Major Activities;
- Responsible for issuing the M/C time analysis in daily, weekly, monthly with high productivity.
- Responsible for yield of RM & PM, reducing the wastes, and losses of quality defect.
- Follow up the process and operation daily by solving problems concerns production or staff in time.
- Applying Best Practices in production area to optimizing manpower and machine utilization.
- Lead daily meeting with quality and maintenance to analyze in depth the reasons for the chronic problems and put action plan resolve it.
- Create a good environment to work, check H&S, plant structure and equipment.
- Preparing operation plan, budget, and investments of the line to achieve the production plan targets.
Production and Operations | Achievement and Projects;
- Number of projects 2, as Team leader.
- Re-engineering design of machine's that reduced cost & staff and improve the quality.
- Adding a new brand.