Plant Manager
AlFouad Group for Automotive Spare Parts
Total years of experience :16 years, 5 Months
Private sector Company, managing and controlling (185) employees in two separate factories, including the following processes: headlight glass lens manufacturing, plastic injection, mold making, electrostatic painting, deep drawing, headlights assembly, sheet metal processing.
Main Tasks:
To ensure the efficient production of goods are of right quantity, quality, and cost to meet customer requirements.
1. Approve planning and scheduling production activities to ensure maximum productivity.
2. Ensure maintenance of cost effective and high standard of production is maintained to meet production volume on time.
3. Participate in making decisions regarding the operating unit’s layout, size and range of products to be delivered also participate in the work processes to ensure smooth operation and lean manufacturing concept are valid.
4. Constantly explore and implement methods of continuous improvement to be able to control production cost and achieve more profitability..
5. Ensure that all policies and procedures of health and safety are properly implemented in the 2 factories to ensure safety for our employees and maintain risk at the possible lowest rank.
6. Approve hiring, training and motivating ideas to all production staff for the 2 factories as required to create a healthy environment for production.
7. Perform staff performance appraisals to enhance their performance.
8. Ensure production & maintenance activities meet with and integrate with Al-Fouad requirements for quality management system, health and safety, legal regulations, and environmental policies.
9. Liaising with different departments to prevent any probable delay.
10. Assesses the need for capital equipment and tooling to utilize production capacity.
11. Develop budgets and approve expenditures for supplies, materials, and human resources, ensuring that materials, labor and equipment are used efficiently to meet production
1. Ensure production departments have sufficient time to manufacture and deliver on time according to the customer’s request.
2.Manage customer order / schedule requirements.
3.Pre-plan production and deploy a daily prioritized work schedule to the shop floor with appropriate time deadline targets.
4.Set, monitor & review work load schedule.
5.Monitor & review production progress against deadline targets to ensure on time delivery.
6.Adjust the production schedule as required and communicate any change to delivery date with the customer accordingly.
7.Monitor & review manufacturing operations to ensure correct quality standards.
8.Ensure that all production related activity is time and cost efficient / effective.
9.Ensure all plant and equipment is maintained & repaired.
10.Ensure production/quality processes, equipment being used and the working environments are all conducive to producing a high quality product / service.
11.Monitor production activity to ensure that the appropriate manufacturing methods are employed and that sufficient due care is taken in order to meet the customer’s build and quality specifications.
12.Ensure rejected product / non conformance is rectified as high priority and that customers are kept informed accordingly.
13.Ensure the correct non conformance paperwork is raised and processed with every reject.
14.Promote & maintain awareness and compliance of H&S in accordance with best practice and legal requirement.
15.Ensure all recruitment and employment is carried out in accordance to company procedure and in compliance with current employment law.
16.Monitor, review and address personnel under performance, maintaining appropriate records in accordance with company procedures.
17.Managing the new projects at AMC, to ensure the ROI and on time - on budget performance is maintained.
18.Provide the required technical support and solutions for both AMC team and customers.
19.Monitoring all related processes KPIs to ensure the achievement for company targets.
• Responsible for managing total quality management activities through:
1. Quality Assurance Section. Sharing in establishing an integrated management system (ISO 9001-2008, ISO 14001-2004, OHSAS 18001-2007).
2. Quality Control Section, Sharing in Technology Transfer Project from the mother Company in Spain.
3. Industrial Methodology Section, Planning for Lean Manufacturing and Six Sigma implementation while operating the factory.
Achievements:
1.One of SWEG's team Key Member of the Technology transfer project.
2.Share SWEG's Team in the Due Diligence activity has been done by Globelec (Generating Power for Emerging Markets), one of the market leaders in the field of green energy projects. (May 2010).
3.Establish SWEG O&M reporting system.
•Managing all quality control activities in an FMCG and automotive feeding industry (In-process and Final Product Inspection) through 24 different production departments.
•Reconstruct the Quality Control Management, adding highly qualified calibers.
•Identify FAC's system weaknesses and strengths through SWOT analysis.
•Apply and move the required corrective actions to ensure the quality system effectiveness.
•Identify Cost of Poor Quality, and Sources of waste to be eliminated to reduce its related cost.
•Preparing and sharing in training programs for FAC's Team (Engineers, Technicians, Quality Inspectors), to improve their skills. "Training programs, such as Lean Manufacturing, Facility Planning, Quality Concepts, Using Quality Tools, Toyota Production System, …etc".
*Introduce Minitab software as a strong SPC tool.
•Apply quality circles, and the related brain storming activities for problem solving techniques to find out root causes and solutions for our customer complains, and technical problems.
•Establish the quality control performance measures, and Quality Data Base.
•Share our Top Management in setting and constructing the new FAC's organization structure and its instructions.
•VW Project manager.
Achievements:
• Sharing FAC's team in quality improvement projects which save a lot of wasted money through changing some suppliers who are not capable to support with the required quality level by FAC, which leads to high productivity, low material consumption and higher quality levels.
•Minimizing the rejection rates (internally and externally) to the minimum levels, and customer complaints to gain their satisfaction and loyalty.
•Keep FAC's Sigma level more than 4.5, and improve some filters quality to be competitive in the international markets and reducing cost of poor quality.
• Share FAC's team to be ISO-TS 16949 and ISO 9001-2000 Certified.
Managing all aspects of the Quality Department (Laboratories, Inspectors, and Technical issues).
Promoting Quality and continuous improvement throughout the company.
Issue quality control instructions and related processes.
Follow up on customers quality feedback for appropriate action.
Support Business Development Department in ensuring prompt Q.C test reports and release of new products.
Preparing the APQP, and the PAPP documents to develop the required counter measures to avoid repetation of problems in new products.
Applying all aspects for ISO 9001-2000 and ensuring their compliance and continual improvement.
Meet the Quality requirements of all major Automotive companies such as Land Rover, MG Rover, Honda, CABI, Daewoo, DC, Nissan and Peugeot.
Carrying out a number of tests on brake discs & drums produced for the LandRover Defender & FreeLander models, MG Rover in MIRA laboratories in UK on April 2003.
Liaison with customers on any concerns and their effective counter measures, using "8D's" reporting and "root cause and effect analysis techniques".
Supporting Project Management in respect to Quality and Business Development input on the introduction of any new project.
Establishing teams and managing the product improvement analysis on daily basis.
Certification from the American Society for Quality
B.Sc. Degree in Mechanical Power Engineering from the Faculty of Engineering
