Plant Manager
Kimberly Clark
Total years of experience :16 years, 8 Months
In one of the Market leaders in Tissue Manufacturing. I am leading Saudi Arabia mill operations with around 350 employee / labor and 17 converting Lines.
Key Achievements:
• Initiated cost saving projects that saved around 1.5 million USD per year.
• Made a turnaround in productivity and cost control with the same level of Safety and Quality and improved the overall mill productivity and saved around 2 million USD through improving production lines efficiency, reducing direct labor cost impact and reducing the material usage waste.
• Reduced the Casual Labors by 20 %
• Change Agent for OPEX (Operation Excellence) in the Plant
In one of the biggest biscuits companies in the world I am responsible for the full processing / making area and I am working on some projects related to increasing the capacities and standardizing the making processes to sustain the quality and improve the performance
Key Achievements:
•Improved the chocolate making capacity by 25 % through deep loss analysis and leading the proper corrective and preventive actions in addition to standardizing the process and developing the team
•Developed the standardized procedures and check list to ensure sustained quality and performance
As a third party logistic services company I have to manage all operational and transportation activities starting from receiving new shipments, picking products and dispatching to the customers in a 24/7 operation. I have to strictly follow the tight picking rules of FMCG products in a 20, 000 pallet position warehouse and 1100 SKUs utilizing the transportation Fleet by more than 85% to assure on time delivery and customer satisfaction
Key Achievements:
•Successfully transferred the WH to a new location without affecting / stopping the operation
•Developed and enhanced the team capabilities to achieve perfect customer service results and on time deliveries
In a plant of one of the biggest FMCG food companies in the world I had to manage all the production, maintenance, safety and quality activities for both the Flake and chocolate making sections. I have to develop and manage the yearly budget, cost saving / productivity projects and CAPEXs. Being Cadbury sourcing plant in the Middle East and North Africa we have to achieve all KPIs
Key Achievements:
•Improved Overall Equipment Effectiveness (OEE) by 20% through deep loss analysis and leading proper corrective short term and long term actions.
•Reduced the head count by 20% and developed the team to achieve our KPIs although we had 10 % increase in volume
•Successfully commissioned with both the Project and R&D teams the new chocolate making tower as part of a 200 million EGP project to increase capacity by 30 %
•Conducted the factory acceptance testing of the new Flake Line and the transferring system in the UK
•Managed a CAPEX of 5 million EGP
•Passed Kraft global quality and safety audit
•Leadership member in the IL6S (Integrated Lean Six Sigma) program
Managing the full operation of the Flake and the Molded Chocolate production lines and ensuring the adherence to both the quality and safety standards in a 24/7 organization with 80 SKUs and 350 employee
Key Achievements:
•Restructured the team that consists of 350 employee to enhance and sustain the performance
•Developed a skill matrix schemes to enhance the operators capabilities and skills
•Successfully commissioned with both the Project and R&D teams the new mold line as part of a 90 million EGP project
•Conducted the factory acceptance testing for the Caramel kitchen machine in Germany
•Developed the required trainings and SOPs that enabled my team to smoothly operate the new molded chocolate production line
•Maintained and improved the operate maintain mindset in the section
•Key member in the safety risk assessment team and the internal quality auditing team of the whole plant
Key Achievements:
- Productivity Improvement by 17%
- Over Head cost per dozen decreased by 5%.
- Headcount decreased by 15% vs. 10% increased volume
- Improved Overall Equipment Effectiveness (OEE) of our pilot production line by more than 25%
- Change over time reduction by 50%
- Implemented lean manufacturing system to one of our production lines.
- Participated in the certification of ISO 18000 and the re-certification of ISO 14000
- Zero LTA (Lost time accident)
Key Achievements:
- Achieves production plan targets with excellent customer service and optimum human resource utilization.
- Managing the production work orders through the ERP system (iScala).
- Implemented the standardization and work place organization system as part of the 5S.
- Developed a maintenance / corrective action system to monitor / organize the maintenance activities, corrective actions effectiveness and spare parts
- Managed the safety activities and the preparation for the global audit
Key Achievements:
- Developed the labor’s soft and technical skills to support the business needs and for better utilization of the human recourses.
- Developed the production team to manage the quality control activities
- Developed a preventive maintenance programs for all machines.
- Handled several safety projects with the SHE department (LOTO, Minor Intervention, JSA, ...)