Production Process Manager
Egyptian British Automotive (EBA) MG Importer
Total years of experience :18 years, 10 Months
1. Managing production process to be more efficient with the aim of reduced lead-time to production, shorter production cycle time and reduced work in progress (WIP) inventories as well as bearing in mind company’s strategic objectives
2. Manage, lead and direct production dept subordinate to achieve production plan
3. Sharing top management board in new projects feasibility studies, giving technical recommendations and highlighting important technical issues to facilitate investment decisions
4. Responsible for production lines layout development for new projects and facilities allocations for best possible performance
5. Apply statistical methods and perform mathematical calculations to determine production processes capabilities, staff requirements and production KPIs.
6. lead process team to issue, control and update:
• Work instructions
• Procedures
• Process sheets and follow up their implementation
• BOM update
• Technical changes & their implementation on the production line
• Quality gates reports
• FEMA study to co-operate with quality dept
• Managing Kanban, 5S & lean-M activities and contacting with the concerned parties
7. Solving problems on the production lines related to production processes and making the required investigation
8. Deploying continuous improvement thinking among team members, providing new ideas & follow-up their implementation
9. Monitoring software & electrical equipment used for assembly processes and contacting the development company for any support needed.
1. Plan, organize and control production to ensure that the products are produced efficiently, on time, within budget and according to standards.
2. Create and suggest proposals to increase production capacity and making action plan for it.
3. Manage, maneuver and utilize our huge manpower (≈450) and deciding human resources required for achieving our mass production.
4. Analyze performance, quality level and availability to achieve best possible OEE.
5. Develop, evaluate and improve assembly methods by utilizing knowledge of workshop layout, materials, parts, assembly processes, lean initiatives, tooling, production equipment capabilities and quality control standards.
6. Interact cooperatively with R&D department to improve our products and find new ideas to minimize any non-added value in our production process.
7. Ensure that the targeted quality standards are applied before, during and after production.
8. Follow up the quality audit systems and react with the corrective actions to improve quality and reach the target audit points.
9. Lead, motivate and supervise subordinates in the different assembly lines.
10. Improve employees’ technical competencies and training activities.
11. Appraise the performance of the subordinates and check employee’s reports in the section.
12. Follow up health and safety regulations and insuring the implementation strategy.
1- To develop, evaluate and improve manufacturing methods, by utilizing knowledge of materials, parts, Assembly processes, tooling, production equipment capabilities, assembly methods and quality control standards.
2- Analyze processes: cycle timing work studies, balance tasks to meet time requirement
3- Analyze quality issues by using problem solving techniques.
4- Estimate production times, staff requirements and related costs to procure information for management decisions
5- Confer with management, engineering and other staff regarding manufacturing capabilities, production schedules and other considerations to facilitate and improve production processes.
6- Participate and implement Lean initiatives and any other improvements within the area
Health & Safety Responsibilities:
1- Ensure all equipment & machinery meets or exceeds statutory regulations
2- Ensure all equipment and machinery risk assessments are completed.
Responsible for self and others
1- To cooperate fully with all safe working practices
2- Contribute to the implementation of such practices when necessary requirements
1. Achieving the monthly target according to the monthly production plan.
2. Analyzing and solving any accidental / frequent production problem or any bottlenecks.
3. Execute production line balancing, processes simulation & evaluation, time study analysis and performance indication for the production lines.
4. Managing technicians and organizing there work in order to achieve our requirements.
5. Planning and implement preparation for new models; analyze tool needs, supervise new processes, sharing with the German team to apply new models in BAMC (X3 model was my own project).
6. Cooperate with maintenance, logistics and quality departments to apply lean manufacturing principles.
6. Assuring the quality level assigned form our quality department and recommended from BMW Germany.
7. Sharing in the (First Run Project) with Quality department for none defected products.
8. Play a fatal rule in the quality improvement process with cooperation of quality dept (M1 model Quality Improvement) “International quality standards applied on automotive suppliers (ISO/TS 16949/2002)”.
1. Responsible for mechanical and electrical department.
2. Giving tasks to technicians.
3. Observing their work, directing them by technical information and finalizing their work.
4. Supporting with the all-technical data required.
5. Contact the Chinese technical department to get the required technical data.
6. Achieving customer satisfaction.
1. Observing production process over 15 injection molding machines to achieve daily production plan
2. Raise daily production reports to production manager
3. Co-operate with quality department to meet product specification and minimize defects and waste
4. Adjustment for variable parameters of the machines after die changeover process
5. Communicating maintenance department to perform technical troubleshooting
6. Lead, coach and train supervisors and operators
High Degree Diploma in Engineering Management which includes: - Project Management, - Economy, - Marketing, - Production Management & Lean Manufacturing, - Statistical Quality Control (SQC), - HR, - Regulations, - IT Fundamentals, - Technology Management.
Faculty of Engineering, Helwan University B.Sc. Degree of Mechanical Production Engineering 2004. GPA: 2.5/4