Plant Manager
Lighting Technology Company
Total years of experience :26 years, 6 Months
Achievements
• Increase the production output from 30, 000 unit/ month to 128, 000 unit/ month.
• Decrease labor cost from 9 SAR/ unit to 4 SAR/ unit
• Save 4.5% in raw material cost ( 3 MSAR saving in Y 2016)
• Increase company product range ( LED, solar system)
• Decrease raw material stock from 27 M to 18 M and decrease the WIP from 4 days to 1.5 days
• Lead the implementation of ERP system (SAP) in our manufacturing unit. Project completed within 10 month
Key Responsibilities
Plant Management
• Manage plant operations including planning, scheduling, organizing, coordinating directing and controlling all activities to achieve daily, weekly and monthly targets
• Supervise operations monitoring adherence to established policies and procedures assuring efficiency and safety and product quality
• Review and revise processes, systems and procedures to optimize utilization of resources - manpower, equipment, facilities, materials and capital - to minimize manufacturing costs
• Coordinate with the sales department in preparing and executing production plans to ensure delivery of products to customers as per requirements on time.
• Define and control process parameters ensuring consistent quality of products and reduction in quality related costs including rejection and wastage.
• Establish quality standards and monitor quality control activities from raw materials through production stages to final product to deliver quality products to customer.
• Plan and execute continual improvement programs including improvement of methods, systems and procedures to enhance performance and productivity
• Develop and implement preventive and routine maintenance schedules for all equipment and coordinate quick repair of breakdowns to deliver targeted plant availability and reliability.
• Manage projects for plant expansion, installation of new equipment and development of new products including feasibility studies, budgeting and project management.
• Implement all health, safety & environment (HSE) management policies, rules and regulations and monitor consistent compliance across the plant.
Purchasing and Supply Chain
• Analyze detailed production plans and prepare material plans to procure, stock and make available all raw materials, consumables and spares for operation.
• Manage the procurement cycle from finalization of requirements, issue of tenders, evaluation of bids and quotations, negotiation and award of orders and expedition of deliveries.
• Develop and manage a pool of resourceful vendors for sourcing requirements from international and domestic markets at the most cost-effective prices and terms.
• Supervise the operation of raw materials and spare parts stores and finished product warehouse covering all aspects of receipt, accounting, storage and issue/dispatch.
Finance and Cost Control
• Lead the process of formulating annual operation, maintenance and capital budgets in coordination with departmental managers, sales and purchase teams and senior management
• Monitor costs and expenses under various heads on a regular basis, identify major variances and implement effective corrective plans.
• Coordinate all finance activities including working capital management, funds management, accounts receivables and accounts payable to maintain profitability of operations.
Administration
• Ensure provision of employee support services including transport, canteen, grievance handling processes to ensure employee satisfaction and performance
• Monitor and ensure maintenance of all required records and returns, availability of licenses and permits for statutory compliance of the operational function.
Sales and customer Support
. issue price list
. Issue the products data sheet and company catalog
. Develop the new products as marketing team request.
. Visit the client and attend Seminar to present to the clients the advantage of our products.
. Sharing in the yearly workshop to issue company and marketing strategy.
General Cable Group has been an industry leader and innovator for 170 years. Today, it is one of the largest wire and cable manufacturers in the world.
Role
• Managed all aspects of planning, production, operation and maintenance, quality, design, process engineering and purchasing contributing to achievement of business plan objectives.
Achievements
• Increased plant capacity by 50% without new investment by applying lean manufacturing concepts, 5S, improving machine efficiency and utilization and introducing 4-shift working.
• Expanded the company’s product range leading to increase in annual sales volume. We added instrumentation cable, fire cable, flat cable, and overhead cable.
• Implemented WOW project (ware on waste). As a result the operation cost reduced around $500, 000/ year
• Decreased product cost around 15% using alternative materials and improving manufacturing Technic.
Key Responsibilities
• Planned, scheduled, coordinated, monitored and controlled all plant operations to achieve objectives of production, product mix, quality, cost and safety.
• Coordinated with the sales department to align production schedules to customer requirements an ensured on time deliveries to satisfy customer expectations.
• Managed all quality control activities across the production cycle from raw materials through work in progress to finished goods to maintain company quality standards
• Established and monitored compliance with process parameters to deliver products of consistent quality with minimization of rejection and wastage.
• Monitored and controlled operation and maintenance costs, ensuring optimum utilization of all resources to achieve targeted operating margins.
• Managed the procurement of raw materials and spare parts ensuring availability for production with optimum inventory levels.
• Led projects for expansion of production facilities, development of new products and improvement of existing processes to meet growth and performance objectives of the company.
• Supervised, trained and motivated engineers, supervisors and workers building and sustaining an efficient team delivering superior performance.
• Implemented continual improvement programs to enhance the existing product offering, studied the markets to understand customer preferences and developed new products to fulfil market demand.
• Developed and implemented preventive and routine maintenance schedules for all equipment and coordinated with maintenance teams to address breakdowns to reduce machine down-time and delivered targeted output.
• Managed the warehousing function, handled receipt, accounting, storage, preservation and issue / dispatch of incoming materials and finished products.
EG Metal Industries produces continuous cast copper rods using the technology of and with technical support of Southwire Inc, one of the biggest manufacturers of continuous cast copper rods in the world
Achievemnts
• Joined EG Metal at the start-up stage and executed installation and commissioning of all plant machinery for timely commencement of operations.
• Improved profitability by controlling material consumption and scrap generation maintaining operating costs under the budget. (Scrape reduction 0.5%, operation cost reduction 25%)
• Reduced shipping cost by increasing tonnage qty inside the container
Key Responsibilities
• Led production activities planning and executing schedules to produce products as per customer requirements of specification, quantity and quality.
• Reviewed all production processes, identified inefficiencies including process and system bottlenecks and implemented effective corrective actions
• Implemented measures to optimize consumption of resources and minimize wastage to improve operational margins and plant performance.
• Developed resource schedules and material plans, prepared procurement schedules and coordinated with the purchase department for availability to achieve production targets
• Developed and updated daily, weekly and monthly production schedules based on order position and stock availability to maintain optimum levels for finished goods
• Implemented continual programs for improving existing products and develop new product to meet market and customer demands
• Coordinated with the finance department in analyzing production costs, identifying opportunities for savings and implementing appropriate action plans.
• Managed the warehousing function dealing with receipt, accounting, storage, preservation, issue/dispatch of incoming materials and finished products.
• Implemented and enforced compliance with the company’s health and safety policies, rules and regulations ensuring safe execution of all production jobs
• Supervised, motivated, trained and developed engineers and workers to improve overall performance and productivity of the production department.
• Improved work methods, systems, and devices to increase operational efficiency, and eliminated redundant activities through rationalization of tasks.
BICC Egypt, established as a JV with BICC Cables UK was acquired by General Cables Egypt in 2010
Achievements
• Joined BICC Egypt at the start-up stage and contributed to successful and sustainable operation for 4 years; executed installation and commissioning of plant machinery.
• Expanded the company’s product range based on the study of customer demands and market dynamics. ( range increased from 16 - 185 sqmm to 6 - 1000 sqmm)
• Reduced manufacturing cost 10% by standardizing the product
Key Responsibilities
• Participated in the manufacture of new products and improvements of existing products to meet the expectations of the customers.
• Supervised the testing and commissioning of all new or additional machines installed in the plant ensuring compliance with ordered specifications.
• Improved overall production efficiency by reviewing and revising all work methods, systems and devices across the production process.
• Supported plant management in analyzing and resolving day-to-day process, plant and product related problems and issues.
• Developed standard operating procedures and work instructions for safe and efficient operations of all production equipment and machines.
• Monitored the condition of process tooling and followed up for manufacturing of tools to maintain tool availability and quality.
• Supervised receipt, inspection and upkeep of all newly procured tools and dies ensuring availability as per production requirements.
• Looked after the calibration of all equipment and measuring tools as per approved schedules and appropriate methods and techniques.
• Managed quality control of incoming materials, in-process goods and finished products through appropriate inspection and testing.
• Lead the improvement team to eliminate wastage, increased efficiency and reduced operational overheads.
Elsewedy Cables manufactures low, medium, high and extra high voltage power cables, control cables and overhead transmission lines
Key Responsibilities
• Supervised production operations of the assigned plant area ensuring output meeting the daily target established by the production manager.
• Monitored production activities and controlled process parameters to assure production of products meeting order specifications.
• Coordinated with supervisors and machine operators ensuring communication of production schedules and provided technical and logistics support to achieve targets.
• Supervised the on time preparation and documentation of all prescribed production report on time ensuring accuracy and completeness.
• Monitored and ensured correct identification and proper handling of work in progress and finished products stored in the production area.
• Identified and controlled non-conforming products on the shop floor adhering to the approved policies and procedures.
• Monitored material consumption and scrap levels and reported variances from the design requirements for appropriate corrective actions.
• Participated in implementing programs for achieving continual improvements in plant performance, productivity, reliability and safety.
Graduate Diploma in Mechanical Engineering , Sep 2003 – May 2005
Professional Diploma in Project Management, Sep 2001 – May 2003
B.Sc. Mechanical Engineering, 1986 - 1991 Professional Development Management and Leadership Training • Leadership and Organization Behaviour, Krauthammer Institute, 2014 • Team Building, Nov 1997 • Supervisor Skills, Nov 1997 • Improvement of Administrative and Leadership Skills, Cairo University, 1996 Quality Management Training • Lean Six Sigma Green Belt, France, 2012 • CE Mark, 2005 • Requirements and Implementation of ISO 9000 and QS 9000 Quality Management Systems, American University in Cairo, Sep 2001 – Jan 2002 • Quality and Environment Program Audits, American University in Cairo, Sep 2001 – Jan 2002 • Statistical Quality Control, Arab Office for Quality Improvement, 1996 • ISO 9000, ICL, 2000 Technical Training • Continuous Cast Copper Rod Technology and Plant Operation, USA, Jan 2001 • Engineering Management Course, Cairo University, Sep 1999 – Apr 2000 • Fire Fighting Course, Jul 1998 • Tool and Die Design and Process Control Techniques, BICC Group, Dubai UAE, Dec 1996 • Hydraulic Circuits, Cairo University, 1996 English Language Courses • Technical Language and Report Writing, American University in Cairo, May 2002 • Intensive English Program at the English Language Institute, AUC – TOEFL Score: 517, Jan 2000 – May 2000 • English Course, British Council, 1997 and 1998
