CV, Manufacturing, Operation Director Looking Globally

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Serial No: 42070

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Skills keywords: maintenance, manufacturing director, plant management, plant operation, quality management, supply chain management

Current location:  Egypt - View on map

Nationality: Egypt

Preferred Sector of Employment:  Manufacturing and Operations, General Management

Spoken languages: Arabic, english

Location I am interested in working: Anywhere

Profile

Operation Professional with excellent people Management capabilities and employee motivation. 12+ years in Multinational manufacturing and new products development of FMCG’s in Middle East. 8 years of professional experience with Nestle working with processing, innovation and renovation of products. Experience includes: Multi sites running, operational performance, new product developments and employee motivation.

Business Experience

2014
Wadi Food, a Company of Wadi Group, (Egypt)
Position: Senior Manufacturing Manager
Reports To: General Manager and fully accountable for Operation of 3 operating sites in Egypt with all operation / Research & Development functions.

Achievements to date:

Plants Performance:

• Ensure that Plants have a detailed loss and waste analysis in place (based on OEE) and structured data-driven and Team-based continuous improvement process. • Ensure efficient and effective operation of all processes within control to achieve Key Performance Indicators (KPIs) in Company Business Plan/Objectives through Lean manufacturing Techniques. • Ensure all Quality and Customer acceptance criteria are met for products manufactured in the Plant • Ensure production of the correct specifications of products is achieved on time and in full manner. • Follow up closely with engineering manager about lines and machines overall equipment effectiveness (OEE) and agreed on maintenance and overhauling activities within the agreed timing within TPM program.

New Product Development:

• Working on NPD (new product development agenda) from marketing idea to production reality. • Identify opportunities to manufacture new products or to improve the manufacturing processes that generate revenue by creating greater Customer value or eliminating waste • Identify, asses and qualify product lines for new products computability. • Careful selection/ approval and qualifying of suppliers (local / foreign). • Participate in new product costing / identify possible alternatives for optimize Quality/cost.

Operational Excellence:

• Ensure all procedures and systems are maintained in accordance with ISO Standards. • Provide leadership to Operational Excellence by ensuring it becomes “way of working” activity. • Leverage & benchmark against internal & external operations. • Provide hands-on leadership of problem solving activities • Lead the process for developing and communicating Plant business plans and goals to ensure improvement.

People Management:

• Develop direct reports by providing clear accountabilities, expectations and feedback to improve performance. • Effectively schedule and utilize staff for Plant operations and Operational Excellence activities to ensure maximum Plant utilization, reliability and improvements. • Develop effective succession and recruitment plans to ensure a depth of knowledge and leadership within the Plant and seamless transition of key roles • Ensure (at a minimum), annual assessments are carried out on all staff with a focus on knowledge, competency, performance and future career development and training needs.

Quality, Health and Safety:

• Ensure Compliance to and maintain an effective approved HACCP plan, ensure all CCP’s are managed accordingly. • Responsibility to ensure NCR and CAPA corrective actions are completed and actions implemented within agreed timeframes. • Ensure H&S activities are consistent with Occupational Health and Safety Framework and good performance and leadership is recognized and rewarded. • Ensure any non-conformance against safety procedures/policies are dealt with within agreed time frame. • Demand a high level of ethical behaviour and team participation in H&S activities including driving structured problem solving of incidents. Safety Work Practices observations, audits, hazard reporting and management, incident reporting and management and health and safety training.

2012
Fromageries Bel, Middle East
Position: North East Africa and Middle East Trade Quality Manager

Responsible for insuring Optimum Quality of manufacturing products and Supply chain cycle from the loading step till customer receiving as well as distributer Audits ,whole sellers, retailers, modern and traditional trade visits and upgrading to insure product Quality and availability for the Middle East countries

Achievements:

• Ensuring that Bel Warehousing and Transportation standards are met by the distributors and wholesalers and the monitor of the Trade stocks by channel will have a major impact on the quality and shelf life of products in the Trade. • Distributors SC capabilities assessment (Quality processes: Quality monitoring scheme, traceability) • Support implementation of standard QA system at distributors • Logistics processes audits (Warehousing ,shipping and transportation) • Monitoring of action plans with Sales , SC and Distributors • Development with Technical packaging the Co-packing standards • Ensure/Document and communicate results of trials (Packaging specification) • Deployment of a statistical quality control process during the reception • Implementation of an efficient claims Management process • Coordinate the EQC audits ,analyze the results and propose improvement actions • Distributors capabilities (People, Systems and processes) • Complexity of the Bel SC and route to market and long lead times from production to the shelf • Coordination with Distributor and Sales to implement the action plans. • Main KPIS: Distributor´s compliance rate to the Storage and Distribution good practices, Non Quality costs, Adherence to the Claims management process. • Traceability Audit in Distributors warehouse

2008 – 2011
Fromageries Bel, Cairo, Egypt
Position: Site Manufacturing Manager

Responsible for overseeing all daily operations of the plant from manufacturing ,Quality and Maintenance and insuring that policies and procedures are followed while Supervising and motivating staff members .

Achievements: • Understanding strategic vision, mission and purpose for the site running, while effectively communicating associated action plans and progress to employees to fulfill this mission and vision. • Maintaining a clean Plant free of safety or health concerns, with always cared production equipment and machinery to avoid any delay in manufacturing and ensure quality control standards are upheld. • Ensure cost-effective manufacturing of planned production, while meeting the production schedule with best quality and safety at lowest possible costs.

• Ensure that the plant achieves / exceeds line productivity and efficiency targets and being accountable for overall lines’ efficiency, yield, rework, overweight, scrap, line manning, and production volume. • Responsible for productivity and projects in conversion, Deliver overall financial results that exceed budgeted standards, and achieve productivity requirements, Responsible for budgeting, and adherence to budget figures, tracking and reporting of deviations when existing. • Ensure all quality (HACCP, GMP, ISO) and safety regulations are in place, monitored and followed by corrective actions when needed, ensure that all products produced at lines are complying with product specifications and Support HSE programs and reinforce safe behavior of Manufacturing team members.

Nestle, Cairo, Egypt 2003 – 2008 Position: Production Manager

Responsible for Managing overall production, quality, personal hygiene, cost reduction and Control through the whole process according to standard legalizations and according to Nestle best practice and GMP regulations.

Achievements: • Ensure that Nestle industrial operations and general instructions fully applicable and results obtained reflects sustainable excellence in terms of Quality, food safety, Cost Service (reliability, flexibility and speed). • Continuous review of key performance indicators (KPI • Creation of production plan based on sales &marketing forecasting and Identify methods to improve efficiency, performance & decrease losses. • Innovate new products and renovate the existing ones (through creating different alternatives, new flavours, new recipes, creative solutions, etc). • Evaluate suppliers, raw &packaging materials in terms of quality, • Setting annual department budget and identify cost saving opportunities. • Motivate production operators and production workers.

Nestle, Cairo, Egypt 2000 – 2003 Position: Deputy Production Manager

Responsible for Implementing Nestle systems of GMP, Haccp, Hygiene, personal safety, sanitation, production control, cost monitoring and control.

Achievements: • Implementing Nestle systems of GMP, Haccp, Hygiene, personal safety, sanitation, production control, cost monitoring and control. • Co-ordinating development activities. • Identify cost savings opportunities, Development and motivation of workers and machine operators. • Over all supervision of headcount of 240 person working 24/6. • Participate in new product development testing sessions .

Al Ahram Beverages(Heniken), Cairo, Egypt 1998 – 2000 Position: Research & Development specialist

Responsible for creation / innovation of new flavoured malt beverages.

Achievements: • Innovate new products and renovate the existing ones (through creating different alternatives, new flavors, new recipes, creative solutions, etc). • Evaluate suppliers, raw &packaging materials in terms of quality, Safety and hygiene and technical assistance to factories.

Professional Development:

Multinational experience and mentality with world number one food company.

• Managing production operations of production factory with a work force of over 300 employees.

• Managed the production and set-up of new Manufacturing lines of (Take home) ice cream, biscuit cones, processed cheese.

• Continuous establishment ,monitoring and reviewing of key performance indicators (KPI’s) for accomplishment of smooth business run while identifying the most simplest ways for improving the current status.

• Decrease process complexity to achieve cost reduction of processed cheese manufacturing leads to decrease raw losses by 0.5 % in 2008 and 0.9% in 2009.

• Initiate cost reduction program of biscuit cone rework which leads to decrease losses by 4%.

• Reduce usage variance (packaging) to decrease losses up to 10%.

• Team building of preventative maintenance team for pre -expectation of lines break downs before occurring leads to decrease line stoppages by 20 % in first 6 months.

• Implementation of Nestle Globe project with SAP /R3 computer program.

• Implementation of SAP in Bel Egypt.

• Motivate operators and workers for fire fighting and first aid teams to decrease injury in production environment as per Nestle principles for safe work place program.

• Professional Training

Production & supply chain Management

Decision Making and problem solving.

Effective negotiation skills.

Time Management.

OHSAS 18001 Awareness.

Train the trainer.

Managing change.

Skills development program for sales and marketing Managers.

Communication skills.

Safety Standards.

Advanced Fire-fighting systems.

Industrial safety.

5s and process mapping

Operation Management

Production planning, scheduling and follow up tools

Quality Assurance Management.

Statistical Quality Control (SQC).

ISO-9001 & 22000 Awareness.

Cost Control Strategies.

Process Improvement tools.

GMP and Haccp analysis in food products.

Factory Management System (FMS) .

Recipe Management System (RMS) .

Stoppage Analysis Module (SAM) .

Finance for non-financials.

Business writing.

Lean manufacturing.

Training outside Egypt

2 weeks in Austria for Skills development program for sales and marketing Managers.

10 days in Netherland for knowhow and technical support of beverage professionals.

Successive trading & market visits For the Middle east region (11 countries).

Education

2011-2012
James Madison University (USA),
Certified Manager Diploma
1989-1993
Faculty of Science Cairo University
(BSC. Chemistry).

Language

English,

Arabic