Total Quality Management Senior Manager
Egypt Foods Group
Total years of experience :20 years, 11 Months
Directly reporting to the chairman of the group, Direct operations of Strategy Deployment, Food Safety, Quality Assurance, Continuous Improvement, Customer Relations Management, and Group Compliance by the direct supervision of about 5 Managers and 233 employees.
Main Achievements:
• Detect the gaps to comply with Baldrige Excellence Framework to set 4 years of business plan implementation to achieve 83% from 27% on the Baldrige Excellence assessment score.
• Set and Build a Company Digital Transformation Strategic Plan.
• Set a corporate plan across the group to comply with ISO 22301 for Business Continuity.
• Decrease 21% in customer complaints per every billion products KPI.
• Upgrade CRM Management system to comply with ISOs 10002/04.
• Improve Call Center Customer Satisfaction Score from 71% to 89%.
• Decrease with 27% of chips' lines unplanned stoppage percent due to potatoes' poor quality.
• Create and Manage Group Strategy Management Procedure.
• Create a Continuous Improvement Policy and Procedure for the whole group to manage the implementation of the Continuous Improvement ideas/projects.
• Build, Develop, and Manage product competitiveness reporting procedures.
• Review, develop, and upgrade Chips' Factories Quality Control manual.
• Build a Training and qualification program to improve blue-collar culture regarding Food Safety, Health and Safety, Continuous Improvement, and Total Quality Management Culture.
• Build new QA sections for branches, distribution points, potatoes stations, and refrigerators.
• Build Returns Management policy and procedure led to minimizing 13% in products' returns.
Main Achievements:
• Restructure manufacturing sector, reduced middle management by 6% and blue-collar by 7% to achieve efficient and lean organization.
• Build Manufacturing Dashboard with KRIs and KPIs for the first time for the manufacturing teams to monitor and control performance and ensure achieving the sector's strategic targets and objectives.
• Improve productivity by 7% and set reporting system to measure and monitor OEE.
• Start to implement Lean Manufacturing System, progressing in Lean World Class assessment tool from 7% to 24% compliance percent with the world-class benchmark.
• Improve QEHS (Quality, Environmental, Health, and Safety) Audit Score from 41% to 52%.
• Set manufacturing sector's business plan for 2025 company vision.
• Set concept of make or buy according to available resources and cost-benefit analysis.
• Set S&OP Procedure between sales and operations to ensure the highest agility to respond to sales.
• Lead 3 months cleaning and disposal project for 800 tons of scrapped metals and wastes from the factories.
• Selected, negotiated, and bought used semi-automatic steel cold rolling mill line from Netherland.
• Decrease Manufacturing outsourcing and contracting costs by setting a performance management system for contractors and outsourcers.
Main Responsibilities:
To oversee all daily operations of the plants by the direct supervision of about 1000 employees (6 Managers, 5 Area Managers, 4 Section Heads, 9 Engineers, 42 supervisors, and 800 technicians) from Production, Maintenance, QC, SHE, warehouses, logistics, and lean departments.
Main Achievements:
• ASG plants have been presented by the Egyptian ministry of trade and industry to the Danish Ministry of Industry, Business, and Financial Affairs, as a success story for a local company that has good practices in internal communications.
• LEAN transformation journey and especially implementing mini-company concept has been presented by me as best practice in LEAN Africa Summit 2018 on South of Africa.
• Develop AMS rate "Lean" assessment tool and move forward from 34% to 48%.
• Decrease in Total Recordable Accidents with 83%.
• Decrease External Defective Parts "PPM" by 35%.
• Increase in the Total number of implemented Continuous Improvement Projects/Processes by 150%.
• Total cost savings for 2017&2018 budgets was 7.3%.
• Improve Equipment Efficiency by 11% and Manpower Efficiency by 6.5%.
• Set the concept of mini-companies across all the production areas.
• Restructure and delayer organization with 1 organization layer for an efficient and lean organization.
• Implementing a fully bin location numbering system in warehouses.
Main Achievements:
• 32% decrease in accidents during 2016.
• Encourage employees' reporting for unsafe events in which it increased with 34% vs 2015.
• Decrease Accidents/Incidents Investigations period from 72 days to 38 days vs 2015.
• Build monitor follow up system for Corrective/Preventive Action Plans that resulted from Accidents/Incidents Investigations.
• Improve and digitalize monthly QHSE reporting in which has decreased reporting process time by 25%.
• Improve safety culture by improve weekly safety messages and create internal safety alerts system.
• Increase monthly safety meetings participators with 23% vs 2015.
Main Achievements:
• Managed 6 plants successfully for 6 months with absent of 3 plant managers.
• Built and qualified new team for managing PACKAGED GASES plants with new 3 plant managers.
• Contributed in setting PACKAGED GASES Business Strategic Plan.
• Doubled cylinder's maintenance capacity by improving some areas in 6 months.
• Built Effective KPIs monitoring system for PACKAGED GASES Plants.
• Decreased cost per unit of 4 plants out of 6.
• Decreased Customers complaints of packaged gases plants with 37%.
• Zero "Non-Conformity Reports" for surveillance audits of ISO 9001. 22000. 14001 and OSHAS 18001.
• ALO plant won safest plant of Air Liquid Egypt Subsidiary for 2015.
• Increase warehouses utilization by 11%.
Main Achievements:
• Cost Saving Project counts -2.3% of budget per 2013.
• Improved plant Industrial Management System implementation progress from 57% to 91%.
• Best practice Industrial Management System Self Audit.
• Won “The Safest Plant” at Egypt Subsidiary for 2014 Safety competition.
• Decreased reworked Cylinders from 17.2% to 7.4%.
• Decreased C2H2 gas losses 11% and Decrease unit cost 9%.
• NO NCR for surveillance audits of ISO 9001, 14001 and OSHAS 18001.
• Increase warehouses utilization by 7%.
Main Achievements:
• Receive, commission and Validated equipment and machines that related to embossing line.
• Designed and implement layout of production hall and warehouse according to lean principles.
• Prepared for 20 Work Instructions, 4 Standard Operating Procedures with needed Job Safety Analysis.
• Designed powerful monthly evaluation and KPIs system for operators.
• Prepared training program for transferring knowledge from German expats.
• Passed successfully ISOs 9001, 18001 and 14001 audits without any major findings.
1. Establish the terms, policies of the quality and explain it to the staff and the employees of the company and to train and motivate them.
2. Create, maintain and improve the company quality manual, procedures and forms such as quality manuals, quality procedures, etc.
3. To conduct surveillance and internal audit to all departments and divisions to ensure the application of these procedures.
4. Issue regulations and instructions concerning the application of these procedures and follow-up implementation.
5. Establish the quality control plan and explain it to the quality inspectors.
6. Delivery of the quality inspectors the process sheet of every production, and illustrate the checkpoints.
7. Participate in the evaluation of suppliers.
8. Participate in the evaluation of the performance of staff and workers in all divisions through the extent of their quality system implementation.
9. Supervising the conditions of storage in warehouses in both its raw materials and semi-processed and processed continuously.
10. Respond to customers complaints that received about any product after tests and the necessary investigations.
11. Providing periodic reports of the achievements, problems and failures of the department to the top management.
12. Checking the initial sample before the starting of its producing.
13. Periodically Commission to take decisions relating to defective products.
14. Develop and follow-up the calibration plan of the measuring devices.
15. Permanent development for the department to raise quality rates.
Extra Position: Assistant for the Production Manager
Job Description
1.Production-planning supervision, scheduling for production, preparing production schedules for manufacturing of industrial, commercial products.
2.Making sure operation meets shipping dates according to sales forecasts or customer orders.
3.Preparing the daily production reports.
4.Preparing purchase orders to obtain materials, tools, and equipment.
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