Plant Manager
cortas for food and refrigeration
Total years of experience :21 years, 9 Months
responsible for the plant
• Handling the operation of the following departments: production -quality control -and engineering/ maintenance departments.
• Provide support to Supervisor on the performance and development of processing staff within the team
• Manage existing and develop new and innovative workflow processes in a complex high volume growth environment.
• Communicate effectively to shareholder/managing director regularly sharing metrics on team performance against agreed key performance indicators.
• Work closely with the Derivatives Implementation team to ensure that any process improvements/projects are implemented into process lean.
• Focus on versatility, performance and development of Processing staff and maintenance within the team Leader in Team Projects, resulting in higher quality and output (line efficiency)and decrease process downtime.
• Assist in development of effective procedures, work schedules, and assignment of responsibilities to provide lowest possible unit cost with exceptional quality.
• Hold on-going workout and strategy sessions with team; work with team managers to share and facilitate best practices.
• Lead Continuous Improvement, be innovative, generate ideas to improve area of responsibility and lead changes for improving quality, performance and safety.
Achievements:
• Reduce the cost of packaging by 8% through changing the layout of the bags.
• Upgrade the quality by implementing new procedures and machine settings resulting in decreasing customer complaints from 7% to 2%.
• Prepare and execute the installation of Ammonia freezing tunnels within 15 days.
• Develop professionally the expertise of the staff by daily communication, modeling and short meetings.
• Reduce the in process quality defect by 50% in terms of breakage, crunchiness and overall shape.
• Successfully getting burger king approval after several trials on the product quality, and upgraded liban frite from targeted to approved supplier .
.• Finalizing formulation packaging materials designing and raw material sourcing to ensure best quality and value for the company on all procurement activities.
• Administering the construction daily activities and coordinating with the consulting firm on any deviation or changes needed. Anticipating and resolving any problems, bottlenecks/scheduling and conflicts to achieve on time or earlier deliveries to keep the project on schedule.
• Striving to achieve best practice in construction and steel structure tendering.Providing inputs to tendering and evaluation for enhanced risk management, capabilities and practices.
• Obtaining consent to operate, preliminary health certificate and environmental certificate, environmental clearance and all approvals required.
• Delivering sustainable productivity improvements through creating a culture of continuous improvement, employee empowerment and waste minimization.
• Supporting capacity building, process setup, product certification, service quality assessment and maintenance of quality and safety.
• Getting the electrical approval, municipality approval, building permit and tendering the plant in coordination with the project consultant.
• Developing and implementing enhanced sourcing procedures for chewing gum processing line, packaging machines and raw material. Negotiating rates with suppliers, contractors and consultants to ensure best value for the company on all procurement activities.
• Coordinating laterally between diverse technical teams and vertically across management hierarchy to seamlessly implement - project roll outs and process enhancements.
• Managing all the operation from warehouse to supply chain as well as quality assurance production engineering.
• Auditing, sourcing all raw material packaging material and machineries, putting uo the system and supply chain circle after prices agreement.
• Responsible for budgeting and forecasting, expense reporting, risk management, status reporting, and execution for the plant
• Create project documentation and strategy plans for several projects for Mak for foods industries
• Developed project plans with forecasts, estimates, and resource assignmentfor Mak for foods industries
• Manage the completion of several project lifecycle from inception to closure
• Collaborate with different stakeholders to determine project timeline
• Map projects for budget tracking
• Developed a database management program, leading the team in meeting all project deadlines.
• Hired and trained new team members based on predicted project needs.
Achievements
• Established the plant from scratch, managed end-to-end process including project planning, co-ordination, execution and commercial startup of the plant. Single handedly developed/ formulated the product, sourced raw material, enhanced quality in partnership with the R&D department as well as hired and trained employees.
• Successfully developed the sugar and sugar free product with different type of packaging and product concept adaptation to be exported across 16 countries worldwide
• Managing the implementation of operational best practices using lean manufacturing tools.
• launched a cost cutting program which lead to raw material cost cutting by 28%
• Budgeted effectively, saving 3% in monthly operation costs.
• Championed getting ISO certificate iso 9001/2008 iso 22000/2005
• Launching ishikawa diagrams for better operation and production stream and less downtime and rejects
• Adjust machineries for more efficiency for example one of the machines produce 135pack per min and I was able to make it reach 142pck per min after some modification in the machine and in the production stream
• Sourcing automation and cost reduction of the project by 70% percent by working close with a new supplier
• Manage with plant manager the production manual /organigrame quality manual and standards
Designation Chronology:
• May 2004 - November 2006: Operation Manager
• August 2003 - May 2004: Plant Manager
Accomplishments:
• Successfully installed and commissioned jumbo lollipop line.
• Spearheaded installation and commissioning of hard candy lines as well as established standard manufacturing procedures and processing flow charts.
• Acted as a catalyst in the evolution of operational excellence refurbished hard candy lines by installing and commissioning of Confitech cooker (1200kg/hr) and Euromec candy extruder.
Key Responsibilities:
• Spearheaded all operational department including Quality Assurance, Production, Engineering - Material & Purchasing and warehousing in coordination with all Departments Manager. Reported to the Group COO.
• Established end-to-end quality assurance system- right from incoming material, in-process to finish good and warehousing.
• Facilitated improvements in the plant's KPIs that impact on product quality, safety, efficiency, creation and maintenance of a high performance culture and throughput.
• Pioneered in implementation of new work culture and practices along with decreasing off standard product rejection resulting in increased hard candy line capacities.
• Evaluated hard candy usage values in coordination with finance department.
• Troubleshot and diagnosed operations problems in day-to-day activities/ daily work orders to avoid delays, effecting corrective measures to resolve the same.
• Established inter department communication, flow of information, facilitated co-ordination of the task and co-operation among team members as well as solving various organizational problems.
Key Responsibilities:
• Provided leadership and vision to Supervisors and employees to accomplish task of maximizing throughput, improving quality and customer service, and reducing operating costs. Responsible for quality assurance, production departments and project progression. Reported to the Affiliate Management Representative.
• Partnered with the Corporate Engineering Manager and coordinated with Project Department for construction of hard candy plant, machine installation, utilities and second rice mill installation.
• Provided direct oversight for the operations management team, including production, engineering, maintenance, quality, safety, material control and human resources.
• Established and maintained Good Manufacturing Practices (GMPs) and Standard Operating Procedures (SOPs) for the Production and Packaging operating areas.
• Served as a hard charging leader with distinctive ability to train and lead efficient, goal-focused teams. Recruited and coached staff for hard candy production including Production Manager, Operators, Quality Assurance Inspector, Lab Technician, Quality Supervisor as well as Material & Purchasing Manager.
• Managed sourcing and successfully negotiated with various suppliers of hard candy raw material - packaging material and paddy suppliers. Ensured material resources used are efficiently, cost effectively, available on time, and at optimum quality and quantity levels.
• Coordinated with finance department to change the rice costing, exhibited in-depth understanding of yield and quality requirements and made decisions to improve and protect those requirements.
Accomplishments:
• Administered centralization of packaging and food labeling development of Gandour Group.
• Successfully handled and finalized the “unilabel” project i.e. one label for Canada, Australia & USA.
Other Professional Experiences:
Free-lance Industrial Consulting
• Proffered strategic consultancy during sourcing of snack line (potato chips-pellet frying and extruded puffs) and packaging machine for Al Bayrakdare Company Syria.
• Aided in sourcing extruding snack line and packaging machine for Golden sands company Sudan. Consulted in modifying plant lay-out in coordination with the engineering firm.
• Sourced and presented to Messers MSCC Group confectionary -snack and potato chips lines along with operation management and manpower requirement.
Engineering