Plant General Manager
Engineering For Metal Industries
Total years of experience :25 years, 4 Months
• Revenue Growth: Drove the company’s revenue growth by 200% over three-year period through strategic business development.
• Market Analysis and Expansion: Conducted comprehensive market analysis that identified untapped market segments, leading to the successful entry into three new international markets.
• Strategic Partnerships: Negotiated and secured strategic partnerships with key industry players, enhancing the company’s supply chain and distribution network.
• Product Innovation: Led the development and launch of new products that increased the revenue of the national markets by 25% within the first year.
• Performance Metrics: Designed and Introduced performance metrics and KPIs that provided greater visibility into maintenance, operations, and quality.
• Continuous Improvement: Implemented a continuous improvement program that utilized Six Sigma control, lean manufacturing and Kaizen methodologies which continuously improved the overall plant performance.
• Process Efficiency Optimization: Successfully redesigned the plant layout, optimized workflows and production scheduling, resulting in a 50% increase in on-time delivery and a 20% increase in overall production line efficiency.
• Operations Cost Reduction: Achieved a 35% reduction in operational costs through process optimizations, optimum selection of blackening technology and implementation of lean manufacturing techniques.
• Equipment Reliability Improvement: Enhanced equipment reliability by 40% through the implementation of a predictive maintenance program, significantly reducing unplanned downtime.
• Maintenance Cost Savings: Achieved a 10% reduction in maintenance costs by optimizing maintenance schedules, implementing a robust inventory management system and optimizing the procurement process.
• Supply Chain Optimization: Re-engineered the supply chain to implement just-in-time inventory, which minimized waste and reduced inventory holding costs by 45% without affecting production or delivery schedules.
• Warehouse Optimization: Successfully redesigned the warehouse layout, leading to a 30% improvement in space utilization and a 50% reduction in warehouse operating costs.
• Strategic Sourcing: Developed and implemented a strategic sourcing plan and contracted with new key suppliers which led to a 20% improvement in material quality and a 15% reduction in procurement costs.
• Quality Management System: Designed the company’s quality management system and achieving all the requirements of ISO 9001 certification.
• Products Quality Improvement: Established a Total Quality Management system that led to a 80% improvement in product quality, reduction in quality defects and a 75% reduction in customer complaints.
• Sustainability: Led initiatives that resulted in a 30% reduction in scrap and waste production, aligning with corporate sustainability goals.
• EOHS Systems : Designed the company’s EOHS systems and achieving all the requirements of ISO 14001 and ISO 45001 certifications.
• Risk Assessment and Mitigation: Performed detailed risk assessments and developed mitigation strategies that decreased the risk of occupational hazards by 50%.
• Regulatory Compliance: Successfully navigated the company through multiple regulatory QMS and EOHS internal audits reaching to zero non-conformances and 100% compliance with industry standards.
• Employee Development Programs : Developed comprehensive employee development programs for technical and administrative teams that increased skill levels, productivity, QMS and EOHS Awareness.
• Strategic Business Development: Conducted comprehensive market research that identified untapped market segments and implementation of a strategic plan that led to successful entry into two new international markets and contributing to a 75% growth in the global customer base.
• Strategic Partnerships: Orchestrated strategic partnerships and acquisitions that expanded the company’s national market presence, resulting in a 50% increase in first year annual revenue.
• Strategic Low Cost Marketing Campaigns: Developed and executed multi-channel digital marketing campaigns, resulting in a 20% increase in annual revenue for the past three years and increased brand awareness by 300%.
• Innovation in Services: Proposed and introduced suites of new services that became pivotal market differentiator from the first year of launch.
• Customer Relationship Management: Implemented a CRM strategy that improved customer retention by 25% and increased average customer lifetime value.
• Process Optimization: Redesigned cross-departmental workflows, which increased operational efficiency by 20% and reduced costs by 10%.
• Performance Management System: Designed and deployed a new performance management system that aligned employee goals with company objectives, leading to a 15% increase in overall productivity.
• Stakeholder Engagement: Established a stakeholder management strategy that improved communication and collaboration, resulting in a 25% increase in project delivery speed.
• Project Management Excellence:
o I successfully played a pivotal role as a project general manager assistant in the implementation of a cutting-edge tailored rolling mill for producing steel sections.
o My responsibilities covered the full spectrum of the project’s lifecycle, from initial concept and design through to final stages of execution and operational launch, ensuring on-schedule delivery.
o My proactive leadership was instrumental in managing and coordinating cross-functional fabrication teams, including Foundry Casting, Machining, Welding and Mechanical Assembly.
o And I spearheaded the quality team for navigating complex technical challenges, and enforcing strict safety protocols.
• Performance Metrics: Designed and Introduced performance metrics and KPIs that provide best performance for operations, maintenance, supply chain, quality and EOHS systems.
• Process Standardization: Standardized internal processes procedures and manuals for Operations, Maintenance, Supply Chain, Quality Control, Quality Assurance and EOHS.
• Quality Management System: Designed the company’s quality management system, successfully meeting all ISO 9001 certification requirements. Ensured full compliance with EN standards for product specifications and integrated Total Quality Management principles throughout the organization.
• EOHS Systems : Designed the company’s EOHS systems, successfully meeting all ISO 14001 and ISO 45001 certifications requirements.
• Employee Development Programs : Developed comprehensive employee development programs for technical and administrative teams that increased skill levels and QMS and EOHS Awareness.
An Industrial Company Specialized in Manufacturing Metal Fasteners - Metals Machinery Manufacturing Industry.
• Quality Improvement Initiatives Through Processes Optimization:
o Effectively collaborated with Flat Steel Department operation teams to optimize production processes, significantly reducing quality defects across various stages, including Steel Making, Thin Slab Caster, Hot Strip Mill rolling, Skin-pass mill, Pickling, Cut-To-Length and Slitting.
o Effectively collaborated with Long Steel Departments operation teams to optimize production processes, significantly reducing quality defects across various stages, including Steel Making, Continuous Casting, Bars and Rods Rolling Mills.
• Technical Solutions: Formulated and delivered effective solutions for "Thin Slab Breakout" operation troubles, resulting in decreased operation downtimes and mechanical maintenance, while simultaneously increasing productivity and product yield.
• Technical Innovation: Devised and presented a comprehensive technical strategy to integrate Total Quality Management, Continuous Improvement, Lean Six Sigma, and Zero Waste principles across all organization departments, driving substantial efficiency and quality enhancements.
• Standardization of Processes: Standardized quality testing procedures across flat steel products, long steel products, raw materials and by-products, ensuring consistency and compliance with industry standards.
• Technical Analysis and Process Optimization Expertise :
o Designed and developed the "Material Balance Model for EAF and LF Processes Optimization ", enhancing precision in process efficiency through controlling input materials and their quality.
o Then designed and developed the " EAF Full Processes Optimization Model - Material, Energy and Cost Ffficiency Balances ", enhancing precision in process efficiency and total heat costs through controlling input materials and their quality.
o Pioneered many process optimization initiatives for the electric arc furnace and ladle furnace operations, that resulted in increase in furnaces productivity and a reduction in energy consumption.
• Technical Solutions Expertise:
o Formulated and delivered effective solutions for water leakage in EAF roof cooling panels caused by electric sparks. This initiative led to reduced operational downtimes and maintenance requirements, while concurrently boosting productivity.
o Spearheaded research into alternative cooling system designs for electric arc furnaces, proposing significant enhancements that improved furnace performance.
o Successfully developed new design for ladle aisle layout, with optimized workflows, resulting in increase in overall ladle furnace production line efficiency.
o Developed new design proposal for ladle furnace feeding system, with solution for a defect, resulting in increase in overall ladle furnace efficiency and saving costs.
• Processes Cost Savings: Developed and executed many cost-saving strategies that cut raw material consumption by 2-10% maintaining steel quality and product yield, saving the company millions annually.
• Project Management: Successfully managed hundreds of refractory installation projects during major and minor repair programs for all types of furnaces in the company including Direct Reduction Plants, Lime Calcining Plants, Electric Arc Furnaces, Rolling Mills Reheating Furnaces. Delivered all projects within stringent timelines and budgetary constraints.
• Refractory Process Improvement: Introduced an advanced statistical monitoring techniques that improved the predictability of refractory wear, and also developed with the technical team many techniques for decreasing EAF repairs time.
• Refractory Cost Reduction: Achieved a 10% reduction in steel making plant refractory material costs through technical specifications optimization and strengthening of unshaped refractory materials.
• Material Development: Led a team in the development of a new unshaped refractory material specifications that offered superior heat resistance and durability, resulting in a 30% improvement in performance over existing materials.
• Innovative Refractory Solutions: Developed and presented innovative refractory solutions that could reduce total refractory maintenance and repair costs for Electric Arc Furnace and Ladles by 50%.
• Emission Reduction: Implemented advanced researches on emission control technologies that reduced greenhouse gas emissions, surpassing environmental compliance requirements.
• Safety Standards: Enhanced workplace safety by implementing best practices in refractory handling and installation, leading to a record of zero accidents related to refractory engineering over a four-year period.
• Technical Solutions Expertise:
o Conducted an in-depth study and identified the primary causes of severe longitudinal cracking in API-X70 steel grade. This crucial analysis averted stringent foreign customer contract restrictions and penalties, safeguarding the company from the consequences of missed shipment deadlines.
o Formulated and delivered effective solutions for "Thin Slab Breakout" operation troubles, resulting in decreased operation downtimes and mechanical maintenance, while simultaneously increasing productivity and product yield.
• Technical Analysis and Process Optimization Expertise : Instrumental in developing the ‘Thin Slab Caster (TSC) Process Optimization Model’, enhancing precision in process efficiency and elevating the dynamic control of cooling regimes.
• Process Innovation: Introduced an innovation project for advanced monitoring and control system "Intelligent Mold" which could significantly improve the process efficiency, reduce the majority of continuous casting quality defects.
• Innovation in Steel Purity and Quality Control: Designed New system for Tundish components, Tooling and Techniques to master steel purity "Molten Steel Filtration System", which could open the way for a diverse range of flat steel grades distinguished by superior cleanliness.
A leading Egyptian electrical cables, wires, and LED lighting manufacturer, contractor, and distributor in Egypt - Electrical Cables Industry.
A leading company in Advertising and Publishing in Egypt - Advertising and Publishing Industry.
Bachelor’s Degree in Metallurgical Engineering - Faculty of Engineering - Cairo University
IWE program is considered one of the highest qualifications in welding engineering, it is higher and more advanced than AWS-CWI and TWI-CSWIP, IWE program applies 835+ teaching hours training and four examination procedures that ensures acquiring advanced knowledge in welding processes, materials, design, welding inspection and quality control, including a critical understanding of welding manufacturing applications.