Manager - Manufacturing
Alessa For Refrigeration & Air Conditioning Co.
Total years of experience :18 years, 11 Months
• Leading the Performance toward improvement projects through Continuous Excellence and Focused Improvement methodologies like as Lean Six-Sigma Manufacturing.
• Calculate and improve Standard Time for line's processes to achieve max. Productivity.
• Initiates with the Waste reduction projects through New Projects related to cost saving of quality improvement.
• Line Quality control through working guide, production and Adjustment specifications.
• Leads, trains and coaches to drive continuous improvement efforts to eliminate all forms of waste.
• Report daily to the plant Manager about production performance and target
achievements.
• Maintain line efficiency to meet production goals.
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A. JOB PURPOSE
- Lead the Shift/Area Team by PMP techniques to manufacture the planned volumes while meeting the Customers’ requirements.
-Driving day-to-day Cell (Processing Area) operational performance, including KPIs for Safety, Quality, Cost, Delivery, Motivation and Nature by lean six-sigma manufacturing & TPM techniques.
B. Achievements:
• Establish SCADA system to minimizing production cost by 7% this target done by increasing machines productivity to 30% by using TPM technique.
Project date: jun-2015: mar-2016, Team members: 3 team members
• Minimizing all production cost for aluminum cables by 3% by increasing machines productivity to 200%: This project done by using TPM technique, this improvement on aluminum rod breakdown machine, stranding machines.
Project date: jun-2014: sep-2014, Team members: 5 team members
• Minimizing setup from 7 hours to 1.5 hours: By using lean six-sigma manufacturing methodology especially (QCO) methods, this improvement on wire armoring machine, Extrusion machine.
Project date: mar-2012: jun-2012, Team members: 4 team members
• Minimizing Non-Standard Length for extra high voltage cables from 1.7%per years to 0.2% per years: by using Six-sigma manufacturing (FMEA) methodology from insulation process to finish process.
Project date: jan-2013: apr-2013, Team members: 6 team members
• Minimizing quality problems in cables manufacturing by human errors to 50%: by developing SOP for all process by process teams.
Project date: May-2013: aug-2013, Team members: 6 team members
• Implementation and maintaining 5S program through all factory workshops by 5 team members.
Project date: jan-2011: may-2011, Team members: 5 team members.
• Increasing sheathing cables machines productivity to 120%: This project done by using lean manufacturing technique, this improvement on power cables section.
Project date: jun-2014: sep-2014, Team members: 5 team members.
c. PRINCIPAL ACCOUNTABILITIES
1. SAFETY
- Improve the safety awareness, by developing one point lesson (OPL) methodology.
-Ensure work in safe environment within Production area.
- Enforce the use of all safety procedures by developing work procedures that adhere to safety.
- Investigate in accident and shear the root cause & corrective and preventive actions should take.
2. QUALITY
- Develop (SOP) to ensure the implementation of all procedures in the day to day operations.
- Ensure all quality parameters are met, and that out of specification is analyzed and reduced by addressing root cause.
- Develop (FMEA) to solutions problems & action plans with my team to prevent re-occurrence.
- Develop the (TPM) to implement Autonomous Program to avoid potential finished good product non-conformities & Lead the investigations in case of unconformity in the product.
3. COST
-Manage the Raw material losses & (scrap), through daily/monthly monitoring & analysis to ensure continuous reduction.
-Calculate balance between Raw material and Finish Good and identify the root cause of the gap
- Managing Power saving consumption.
- Manage the assigned team overtime in accordance with Factory utilization
4. DELIVERY
- Implementation of the weekly plan and but re-plan in case of any deviation of the original plan
- Improving Utilization Efficiency for process equipment & OEE to Operation Efficiency.
- Accountable on Process erumpent failure time and try to reduce machine stoppage.
-Responsible to deliver the production quantity depending on production plan.
5. PROCESS AREA
- Lead 5S Implementation in the Process Area.
- Create the suitable environment for Kaizen in the assigned shift.
- Prepare & follow up the yearly training plan for the assigned team.
- Motivating and proper PDS & SOP process.
-Have a wide experience in all cable process especially in low voltage and medium voltage cable.
- Design of tools used for cable manufacturing along production cycle.
A. Responsibilities:
• Design control circuits for machines and fixing its trouble shooting.
• Establish & commission for Power station 4 Mega Watt to feeding our company by cooperation with ABB-Arab.
• Testing and witnessing all substations elements tests MV substations.
• Review protection and control scheme and apply modifications to scheme if needed.
• Giving recommendations according to standard specifications.
• Visual inspections for substations elements such as CB, Power transformers, CT&VT
• Witnessing stability testing for bus bars and transformers.
• Attend and supervising the protection relays final setting tests and its performance like over currents, distance, differential and bus bar protection relays.
Projects Achieved:
• S/S Service building (66/11 KV) in Industrial zone A6 ABB contactor
* installation 22 machines for finishing dept. and for dyeing dept. and fix any trouble shooting happened
• ZAGAZIG University • Bachelor of Engineering, May 2005 • Major: Electrical Machines and Power Department. Grade: Good. • Graduation Project: Title: indoor & outdoor Electrical installations. (Utilization of power electric). Grade: Very Good.
