Usama Bin Hijazy

Implemented and coached Arnotts Operational Excellence Systems roll out in production.
Conducted loss tree analysis on KPIs to determine improvement projects in Savoury category.
Conducted RCA on recurring issues using six sigma tools like Value Stream Mapping, 5S & DMAIC.
Trained staff in basic problem-solving involving Fishbones and 5Why Analysis to develop a proactive
continuous improvement culture.
Coordinated with site functions for Daily and weekly discussions on KPIs (lead Daily Management
Meetings).
Identify and Track cost saving projects for site operations.
Recent projects:
• Consumer complaint reduction on Lack of seasoning on Biscuits
• Improvement in process to minimize biscuit cracking and texture to reduce process waste
• Reducing changeover times on one of the Savoury lines running 22 products and having more
than 400 combinations of changeovers.
Additional responsibilities:
• Site Training coordinator - Managing Training portfolio for the site including training gap analysis,
maintaining the skills matrix, updating the WI and Assessments.
• Site coordinator for conducting annual Business Continuation Plan exercises.

Developed and Implemented Operational processes across the site to achieve better control on the
operations.
Conducted improvement project to reduce Fill/Net weight on crushed Tomato canning line.
Led a capacity and process improvement initiative on the Flavours line to accommodate increased
demand volumes from Lactalis and Chobani.
Developed training modules and deliver training for RCA. Troubleshoot on-line issues, working with
Operations, Quality and New Product Development to problem solve to root cause
• Contamination issue on the peach Aseptic line that caused loss of 109/110 GoodPacks (1000kg
bags costing $2, 000 each)
Developed visual Tier boards and defined agenda for daily Tier meetings to better measure and validate
key manufacturing metrics such as process waste, OEE, throughput, yield and quality issues.
Conducted process Capability studies on different lines (fillers) to control giveaway by 14%.

Managed processing and cleaning operations consisting of a team of 100+ employees. Basic duties included in the
role:
∞ Responsible for all aspects of the execution of the Food Safety Management System and the
implementation of compliance measures relevant to production, and across the manufacturing
environment by harnessing Zero Defects and Zero Waste mindset.
∞ Coordinated with other functions like planning, finance, capital projects, maintenance and QA to deliver
quantity and quality in a timely and cost-effective manner.
∞ Provided support to R&D for new product development and trials.
∞ Ensured safety at workplace by exemplifying the behavioral, procedural and equipment standards to
provide a safe work environment.
∞ Capability building of staff through training need analysis, to foster a high performing culture
∞ Led defect reduction projects by conducting RCA (5WHYs and Fishbone)
∞ Conducted Safety and GMP audits (including bucket walks) around the factory.
∞ Conducted and participated in HACCP, Safety Risk Assessments, Chemical inventory and SOP audits.
∞ Minimized production budget costs through efficient labour planning and optimising production
schedules

∞ Managed the Education & Training Pillar (TPM) activities for Milk Collection division.
∞ Formulated training Matrices for the staff.
∞ Assessed performance of the training and leadership pillars to ensure audit readiness.
∞ Led LDv (Leadership Development Pillar) across Milk Collection division
∞ Responsible for recruitment of employees and interns
∞ Liaised with external training providers to ensure programs are fit for purpose and value for money.

∞ Built Competency Matrix for the factory
∞ Led Training and Development Pilar for the site
∞ Trainer of Basic Problem Solving and Nutrition Quotient for the site.

∞ Responsible for ensuring the production schedules are met with strong focus on personnel and food
safety.
∞ Conducted Root Cause Analysis (using 5Whys and Fishbone) into all deviations, including safety incidents,
quality incidents, breakdowns, unplanned downtimes and ensure corrective actions are suitable and
rolled out.
∞ Coached and led team regarding compliance to requirements of Nestlé Quality, Safety, Environment and
Food Safety Standards.
∞ Led Focused Improvement activities and deliver agreed results in conjunction with the site master plan.
∞ Conducted and participated in reviews of Zoning, Quality and Safety risk assessments and provide
solutions.

∞ Reviewed site Line & Labour Standards for all processing lines to ensure COP is as per budgets
∞ Provided coaching support in implementation of Nestlé Continuous Excellence (NCE) program across
various departments on site
∞ Data preparation for site Weekly Operational Review (WOR) and Monthly Operational Review (MOR)
∞ Reporting of site KPIs to the centre (Vevey).
∞ Prepared capacity utilization data for the factory lines.