Mahmoud Ahmed Eraqi

Focused on Operational Excellence, Continuous Improvement, and KPI-driven performance management.
Scope: Manufacturing household products, blown film, and cartons (chairs, tables, boxes, printed bags, shrink film, egg trays, etc.).
Duties: ▪ Ensure compliance with Quality Management System standards to maintain operational consistency. ▪ Control and optimize critical process parameters to ensure stable, efficient, and repeatable production performance. ▪ Lead structured root cause analysis for non-conformances and ensure effective corrective and preventive actions. ▪ Drive continuous improvement initiatives focused on cost reduction, waste elimination, and efficiency gains. ▪ Analyze production losses, inventory levels, and sales trends to align supply with demand and improve operational performance. ▪ Develop and monitor integrated plant KPIs to ensure performance transparency and support data-driven decision-making. ▪ Collaborate with maintenance and production teams to enhance equipment reliability and reduce unplanned downtime. ▪ Lead process optimization initiatives to improve productivity, cycle time, and output consistency. ▪ Transform operational, inventory, and sales data into actionable insights supporting business and operational decisions. ▪ Coordinate cross-functional audits and ensure sustainable closure of findings and standardization of improvements.

Plastic Chemist, Freelance
▪ Specialized in formulation, material analysis, and plastics applications. ▪ Experienced in troubleshooting defects across plastic manufacturing processes. ▪ Strong knowledge of chemical and physical testing of plastics. ▪ Acted as a technical reference for chemical principles and industrial processes. ▪ Supported development of technical scopes of services and proposals. ▪ Analyzed data to establish reliable cause-and-effect relationships. ▪ Supported new business development activities when required. ▪ Conducted on-site inspections, defect analysis, and field testing. ▪ Ability to work independently or in multidisciplinary teams. ▪ Active participant in professional and technical societies.
Achievements:
✓ Formulation cost reduction - EGY Board for PVC foam board manufacturing.
✓ PVC foam board void troubleshooting - EGY Board for PVC foam board manufacturing.
✓ PVC foam board color deviation troubleshooting - EGY Board for PVC foam board manufacturing.

Scope: Manufacturing multi-layer and mono-layer plastic packaging (Bottles, Jerry cans, Caps, and PET products) using EBM, IM, and SBM technologies.
Team size: 26 employees (QC, QA, IPC, Calibration, Customer Complaints, Continuous Improvement) Duties: ▪ Ensured compliance of all quality systems with international standards through QA audits and maintained alignment with company policies and approved procedures. ▪ Established and developed the QC laboratory, including inspection tools, physical/chemical testing capabilities, and calibration systems for all measuring equipment. ▪ Led continuous improvement initiatives and presented action plans to enhance product quality, process stability, and operational efficiency. ▪ Developed and implemented risk mitigation strategies and contributed to integrated risk & opportunity management and business continuity plans. ▪ Established the full Quality Control system across all plant inspection levels and defined product specifications and quality control plans in line with manufacturing standards. ▪ Managed development and inspection of new and existing molds and participated in supplier validation and technical proofing activities. ▪ Conducted customer approval trials and stability studies to ensure packaging compatibility with customer requirements. ▪ Investigated customer complaints, performed structured root cause analysis, and implemented effective CAPA actions. ▪ Maintained effective communication with internal departments and external customers to ensure quality alignment and problem resolution. ▪ Supported cost reduction initiatives while ensuring no compromise in product quality standards.
Achievements:
✓ Established and equipped a Quality Control laboratory with advanced testing instruments and SOPs covering more than 20 tests for plastic products.
✓ Reduced product returns by more than 85% in 2025 versus the previous year through structured root cause analysis and effective CAPA implementation targeting manufacturing defects.

Scope: Manufacturing plastic packaging (PET products) using IM, ISBM and SBM technologies. Team size: 40 employees (QC, QA, Chemists, Calibration and Customer Complaints).
Duties: ▪ Established QC, QA, and Customer Complaints functions across the plant. ▪ Developed product specifications and QC plans ensuring compliance with customer standards. ▪ Defined raw and packaging material specifications and supported supplier selection based on quality and cost. ▪ Managed incoming and outgoing inspections in compliance with AQL and quality standards. ▪ Led customer complaint investigations, root cause analysis, and CAPA implementation. ▪ Conducted product trials and managed approval processes with suppliers and customers. ▪ Managed the QC lab, including inspection tools and physical/chemical testing systems. ▪ Implemented calibration system for measuring instruments to ensure accuracy and reliability. ▪ Led continuous improvement initiatives and cost reduction without affecting product quality. ▪ Analyzed quality data and production issues to drive improvements and defect reduction.

Scope: Manufacturing of rigid and flexible plastic packaging (Bottles, Droppers, Jars, Jerrycans, Caps and Flexible tubes) using IM, EBM, IBM, Compression Molding, Extruded Tubes Printing, TOP, TSP and THS technologies.
Duties: ▪ Coordinated with departments to align operations with business objectives and profitability. ▪ Developed product specifications and QC plans ensuring manufacturing meets quality requirements. ▪ Established specifications for incoming raw materials and packaging materials. ▪ Led development and inspection of new and existing molds. ▪ Participated in customer trials to agree specifications and ensure product stability. ▪ Defined, documented, and implemented AQL and inspection criteria. ▪ Managed incoming and outgoing inspections to ensure compliance with specifications. ▪ Led QC team and implemented best practices in testing, procedures, and measurement systems.

Scope: Seawater and well water desalination using Reverse Osmosis (RO). Duties: (2018) ▪ Operated and monitored RO units ensure stable performance and water quality compliance. ▪ Monitored key parameters (TDS, pH, chlorine) and adjusted operations for optimal conditions. ▪ Prepared and dosed chemical additives (Antiscalant, SMBS, Caustic Soda, Chlorine) at required concentrations. ▪ Follow up preventive and corrective maintenance to reduce downtime and ensure equipment reliability. ▪ Analyzed operational data including chemical, fuel, and energy consumption for performance tracking.
▪ Prepared daily reports covering production, consumption, downtime, malfunctions, and water cost.