Plant General Manager
Taweel Industrial Group
Total years of experience :28 years, 6 Months
Reporting to the BoD, managed food production plant in Sudan, Khartoum specialized in snacks and juices production with 9 direct reports " production, safety, quality, sales, HR, Accountant, warehouse, procurement, and fleet maintenance",
+ Launched and startup the project within 10 Month ahead of plan with ZERO safety and quality issues.
+ Managed deployment of SPS, TPM, MTO lean strategy, loss prevention techniques led to increase productivity by 20%.
+ Worked closely with Human Resources to write and execute company policies to be inline with corporate standards and local rules, and leading training & development plan, and maintain retention rate more than 98.5%.
+ Worked closely with sales to achieve competitive advantage in the market for product quality, availability, cost and delivery led to achieved market share 30% within 6 months.
+ Build and sustain safety and quality culture in the company through deploying daily management systems to maintain Zero safety and quality incident.
+ Increased profit margins by out sourcing new vendors for raw and packing material which led to 25% cost reduction.
+ Contributed in developing company strategy and kept the factory aligned with the business plan and complying with operating and legal standards with Zero complaint and 100% quality audit score.
+ Defined and implement the optimum structure in the factory to improve team engagement, increase productivity and improving retention rate from 60% to 90%.
+ Led direct implementation of the quality and safety programs to meet company's policies and legal requirements, and provides in job training and conducted regular audits that reduced injuries rates 30% and achieved quality compliance 100%.
+ Increased Plant production capacity 35% and reduced operations cost 25% through implementing lean manufacturing, and loss prevention techniques.
+ Reduced plant energy consumption 20% through implementing energy management system and kaizen.
+ Led engineering teams to provide sustainable service with maximum efficiency, optimum quality and cost through implementing appropriate management and reporting systems, department work plan, work methods and procedures to be complying with company business plan.
+ Implemented process reliability system to eliminate losses led to reduced Plant equipment unplanned downtimes by 35%.
+ Led $1.5M expansion project for new WH with total size 10Ksqm completion with high standard and Zero Safety and quality fauilre.
+ Led plant problem solving system led significantly to increased production of canning line 60%, and packaging line productivity 50% using re-engineering, TPM, 5S, and Kaizen techniques.
+ Prepared projects feasibility study and managed the planning, implementation, budget, review and negotiate contracts, and delivered the TT&T plan to the plant team.
+ Supported the plant to achieved ISO14000 within 6 months.
+ Owned the daily direction setting meeting and Lead the team to deliver KPI's related to Productivity, Quality, Safety, Cost, Deliver and Moral, and sustained records accuracy according to Product Supply foundations.
+ Increased production lines productivity 15% though implementing Run to Target (RTT) system.
+ Improved Process Reliability for bulk line 45% through implementing process reliability system, TPM, and Kazien.
+ Reduced production lines changeover time 60% through implementing SMED system and process control strategies.
+ Supported plant to passed IWS " Integrated Work System" phase 4 within 4 years.
+ Part of a startup team for installing new weighing system with investment $5M led to reduced weight loss 15%.
+ Rewarded as a success story in P&G Global newsletter for contract labor HC reduction by 50% using standardize work tools.
+ Part of Plant Pillars Team for Process Reliability, Progressive Maintenance, Work Process Improvement.
Paper converting and Nonwoven
+ Deal with customer complaints in a professional manner to sustain customer retention rate 100%.
+ Rewarded from company CEO for led new expansion project completion ahead of plan for installing high-tech non-woven production line with total investment $3.5M and achieving vertical startup with Zero safety and quality issues.
+ Led old plant relocation project without safety or quality issues and achieved vertical startup with optimum cost.
Strategic Management - Financial Management - Operations and Information's Management - Marketing and Sales Management
Automation , Process Control , PLC, Communication ....
