Plant General Manager
Coca-Cola Helleinic
Total years of experience :22 years, 9 Months
Full responsible for P&L, Oversee management of all depts. HSE, Engineering, Production, Supply Chain, Quality Management and admin of fast-paced, high volume manufacturing Plant, 5 lines (260 K Case / Day ) producing all CSD NRB, Can, PET, drive and deliver all business needs for Mega Plant.
Achievement
• Achieve 85.5 % top record for True Efficiency in Coca-Cola Bottling Egypt.
• Awarded TOP Achievers for 2022 annual event.
• Best Plant in CCH Egypt Head Count Productivity / Case (Rank 1 for 5 Plants).
• Best Plant in Cost / PHC (Rank 1 for 5 Plants) .
• Best Plant for WUR for all Plants (Optimal consumption for Water across Egypt Plants ) .
• Best Plant in Safety KPI LTIR - Rank 1 in 5 Plants .
• Champion for TPM Deployment in Plant .
• Pilot Plant for data automation and digitalization Project in CCH Egypt
Leading and managing End to End Operations portfolio , SHE, warehouse, logistics for integrated edible oil and Fats Plant IFFCO Suez, Egypt, include 3 Business Units; Refinery, Filling, Shortening and Margarine -, with capacity exceeding 1000 MT/day, integrated with upstream processes departments for Plastic Blow Molding, Plastic injection and tin Sheet Preparation . Holding primary responsibility for the site’s budget and AOP, with full P&L responsibility partner with sales and marketing team and customer service
Leading Complex Site - 2 Factories (11 Line, +800 Work Force, +170 Ton / Day) with full responsibility for P&L ensuring that plant is managed, maintained and operating at world class standards in the areas of safety, Talent, quality, cost and corporate ethics.
•Directs and discuss high levels of safety awareness through 100% employee participation, within his/ her area of responsibility, while at all times using lean and CI principles, to drive a behavioral change.
•Establish and ensure 100% implementation of plant and Corporate objectives and plans for improved productivity and manufacturing cost by executing Departmental efficiency and plant capacity and improvement modification projects
•Establish, maintain and implement working conditions with high levels of housekeeping, that encompasses 5s principles in the plant.
•Drive Full compliance with Government Regulations and Corporate Policies within the area of responsibility. Ensuring 100% adherence to corporate ethics.
•Develop maintenance programmers in conjunction with the maintenance and Process improvement teams to ensure increased asset reliability.
•Ensure departmental performance is maintained within set standards and that Lean manufacturing framework is implemented.
•Ensure compliance with the expenditure budget allocated. Promote continuous operations benchmarking and development of KPI's while driving continuous improvement in terms of cost management.
•Provide leadership and direction to deputies, thus ensuring that organization develops and retains the best people and foster an environment, which allows diverse teams to develop and to make use of its capabilities.
•Co-ordinate and execute business and capital projects to ensure sustainable growth.
Achievements;
Formulating 3 years Master Plan for 2 Biscuit Factories
Developing Performance Management System for the Plant.
Squeezing Stock Take Variance by 25 %. ( 150 K SAR)
Initialing Conversion Productivity Projects by 2 Million SAR
Leading Commissioning New line
Leading Tenth of Ramadan Sites (TOR) 2 Mega Sites, including 4 factories, 18 Production Line, 4 Categories Chocolate, Biscuit, Bars, Candy and Jelly, to improve long term sustainable competitiveness for the business through implementation of CI Tools and methodologies, Lean, Six Sigma, TPM & Balanced Score Card.
•Champion for integrated Lean Six Sigma (IL6S) program implementation inside CTOR sites, for 3 Factories - 14 lines for Building capability inside Management Team and task force, and result with building one unified Operational Excellence program across sites
•Core member in Strategy plan development for TOR Sites.
•Develop IL6S master plan and milestones; maintain it updated through co-ordination with all pillars leaders
•Provide quality leadership and direction to cross-functional team empowered to execute the Lean Six Sigma strategy for process improvement.
•Define and implement process improvements on key initiatives that result in significant improvements in service delivery, increasing organizational effectiveness.
•lead, drive, and sustain the cultural & technical changes necessary to make the business a world class manufacturer
•Drive Manufacturing Sites to focus on Operational Excellence Tools Lean, SS, TPM.
•Provide perspectives on business plans, profitability improvements, and policies & procedures
•Lead Sites Steering committee to Update IL6S assessment and KPIs reports; ensure actions coming out from the gap and follow up on it.
•Lead Business Process Management (BPM) to enable work flow to be more effective, efficient and capable of adapting ever changing environment.
•Participate in regional and global management meetings and play a key role in establishing business and operational strategies
Responsible for Covering MENA Region (GCC, Egypt, Morocco, ……….)
Unique member from Middle East in IFSS Global Team (45 Members Globally)
Deploying in different business areas
Facilitate, train, and coach team members in the use of Lean Six Sigma tools
Delivered over 450 Coaching and Training Hours
Consult with senior leaders to identify potential Operational Excellence (OE) projects and develop project proposals.
Ensure that key metrics are defined, developed, tracked and re-evaluated; and that improvements result in a positive impact for each project.
Serve as a change agent in institutionalizing Lean Six Sigma end to end process quality
Coaching 15 GB Projects, and 2 BB Projects.
Leading Lean Manufacturing Deployment techniques and methdologies in 3 Factories.
Leadingdiffernt Organization functions (Production, QC, Supply Chain, Finance, Admin, IT, .) for understanding and implementing lean manufacturing techniques, methodologies and applications.
Implementing QCSDMT Approach “Quality, Cost, Safety, Delivery, Morale, & Technology”, to meet company targets in order to improve long term sustainable competitiveness, market share, and profitability.
Document plant best-practice and support the development of best practice
Prepare and deliver training (lean Manufacturing, Six Sigma, CI, ….) for key members, promoters and teams, monitoring them while cascading training inside their departments and areas
Prepare annual budget required for implementing lean techniques, monitoring quarterly review for plant budget to detect effect of implementing lean and adhere to reduce overall cost of the plant, through cost KPI’s ( VAPP, Scrape cost /unit, total saving, Capacity Utilization).
Coach and Advice Plant Managers for Lean Initiative Implementation.
Playing Vital role as change Agent catalyst inside the organization to enhance shifting employees paradigm to accept lean concepts and Philosophy
Supervising, preparing 16 key Leaders to be Certified Trainers from Symbios consulting & ODI South Africa on different Lean Manufacturing Aspects.
Deputy Leader for plant DOUBLE PRODUCTIVITY COMMITTEE improve plant productivity by 43 %
Green Spirit Egypt Committee member for optimizing Energy & resources Utilization
Responsible for leading and Coordinating Loss Prevention (property Engineering) Survey, including Risk Management, Occupancy, Protection Exposure and Business Interruption.
- The main responsibility is managing and leading the teams to achieve dept. goals in: -
•1 Production responsible for meeting section targets in (OEE, Maintenance Systems, Managing to implement systems to fix any, equipment failures by using the proper resources and encourage the spirit of accountability of the team to fix all the technical issues, increase line productivity.
•2 Quality (Own the responsibility of the quality of the product and the whole quality system inside and outside the operations boundaries as following: -
Applying the (QA) Quality Assurance system for monitoring each step in the process , and gather the quality check data and perform a statistical analysis on it for each brand taking to the account the attributes and variable parameters of the product and incase of any increase in PPM level more than the alarming limit I should conduct a corrective action plans aiming to tackle the cause which has increased the level of PPM and our response always be fast and proactive regarding any quality issue, also direct the team to report all the Quality Alerts which is being discovered and put the adequate correction action plan, work on updating work procedures to reduce Quality Incidents, effective Implementation of the Quality Assurance Key Elements).
•3 Cost (Annual Budget preparation and Quarterly review i.e. (Operating supply, Over Time, Utilities…etc.), list and owning the saving list and following-up on the saving project.
•4 Delivery (Reduce Change over time using tools i.e. (PokaYoke), managing the production plan and own the products availability and following up daily.
•5 Safety (Effective implementation of the JSA for all tasks which are being done inside production floor i.e. (Work shop, Rebuild area), reviewing all safety check lists and following-up on the updating them frequently, put plans for eliminating all unsafe work conditions and consequently minimizing the probability of occurring of safety incidents)
• Supervise Preparing timing plans, co-ordinates the activities necessary to ensure the successful introduction of new products, product design changes, modifications, engineering change, etc.
• Leads and evaluates the full implications of changes and implements the changes that are required, signing off of new products, equipment, tooling, SQA reports etc., layout requirements & volumes the documentation
• Responsible for engineering documentation eg FMEA, control of document & Assists in Engineering and product Quality manuals.
• Ensures the continuous improvement of methods, tooling, equipment, systems, identifying problems in manufacturing and solve using appropriate techniques eg SPC, value analysis, SWOT, etc.
• Provides an effective day to day engineering support and responsibility for the unit including problem solving for the shop floor, customer, supplier, and other company functions.
• Validates and designs plant and dedicated production equipment,
• Recommends, develops and implements courses of action to continuously improve manufacturing and engineering systems, procedures, policies, activities and reports.
• Ongoing liaison with the quality department and continuous monitoring and enhancement of quality standard.
PROJECTS UNDER MY SUPERVISION
1. PROJECT ENGINEER RESPONSIBLE FOR TRANSFERRING “AML “ACTIVITIES FROM ROMANIA TO EGYPT. PROJECT BUDGET 780K GBP
2. PROJECT ENGINEER FOR NEW LAYOUT & COMPOSTING FOR ACHIEVING SAVING ABOUT 34 %
3. SIX SIGMA PROJECT OWNERS FOR IMPROVING ENGINEERING DATA.
4. CHAMPION FOR REMOTE PRE BLOCKING PROJECT.
• Managing and directing workshop setting, daily production rates, solving any technical,
and managerial problems.
• Supervise Creating detailed process sheets for each W.P.
• Selecting Appropriate materials, and applying suitable heat treatment using “ Key
To Steel, CES, etc”
• Using FEA Techniques in design procedures.
• Apply Statistical & Technical quality control techniques.
• Using CAD/CAM System “DELCAM…”.
Manage and utilize subordinates to ensure that quality and quantity objectives are achieved
Regular meetings and liaison with team and related departments
Ensure implementation of Statistical Process Control and effective self inspection system
Monitor and control scrap and expenditure to set budgets.
Conduct regular performance evaluations, Identify performance deviations and develop
action plans to address these deficiencies
Guide subordinates to achieve overall objectives and maximizes performance
Create an environment which encourages participation in decision-making
Strive for continuous improvements at all times
1. Lean Six Sigma Black Belt (AUC-QA) 2. Certified Change Agent (Elux -Italian Partner) 3.Post graduate Engineering Management Diploma - (AAST) 4.System Analysis and Design - (ICL Egypt , NCC UK) 5.Six Sigma Champion (Symbios Consultant) 6.TPM Trainer (AOTS-Japan)