Sign in

Production Engineer

August 16, 2018

Contact this candidate


Plant Kaizen Leader / Global Lean Coach Feb **** – Present

General Motors North Africa


Recommend Continuous Improvement projects (e.g., kaizen events, point kaizens, major project teams, etc.) based on evaluating operational and financial data and qualitative analysis based on observation and discussion; supported by proposed budget and cost/benefit forecasts.

Project manage approved Continuous Improvement programs by coordinating necessary human and operational resources and setting and implementing budgetary and timing controls to achieve chartered goals.

Coach, counsel and train operational managers and staff to apply, support, sustain and develop a Continuous Improvement culture.

Facilitate and lead Continuous Improvement events as a subject matter expert while empowering operational staff and associates to present ideas and create improvements and solutions.

Leverage best practices gained through Continuous Improvement activities to other activities which would benefit from implementation.

Execute plans individually and by utilizing a cross-functional team to meet/exceed business goals and effective involvement of consultant resources.

Define plans for both short and long term application and benefit

Coach others to enhance their personal performance setting focused targets and expectations.

Provide proper reward and recognition to individuals/teams.

Provide decisive leadership and team facilitation in the face of adversity - define tasks clearly, identify and coordinate resources, and execute CI go-forward plan.

Quickly identify barriers to progress and execute team plan for success in/out of specific events.

Coordinate successful kaizen events with quantified success including assessment and effective sustainment of standard work.

Develop VSM for plant proccessess to identify wastes and translate it into Kaizen events.

Manage own time and to formulate priorities to manage several tasks at once without local or frequent direction.

Identify and plan to avoid potential barriers, and facilitate resolving barriers with sponsors.

Monitor cost, schedule and performance of projects and events.

Evaluate and take remedial actions to achieve sustained success.

Identify training needs in partnership with operational management, and manage/Support need fulfilment. Name: Mohamed Hussein Ahmed

Current Position: Plant Kaizen Leader / Global Lean Coach Current Company: General Motors NAf

Address: 4th district-5 Green Paradise Compound, 6th October City, Giza, Egypt

+2-012-***-**-*** WhatsApp +2-012-***-**-***

Work Experience Email:

Contant Info

Industrial Engineering Lead / GMS Coordinator Jan 2015 – Feb 2018 General Motors North Africa


Drive continuous improvement workshops for waste elimination

Implement 5S improvements to create and maintain a lean work environment

Plant Downtime Analysis using Lean manufacturing tools (Throughput Improvement Process)

Drive Productivity improvement, and set plant Productivity benchmark with the IE Global team.

Process Timing Evaluation by conducting STDS studies (Standard Time data Sheet) for Work Steps and Workload Balancing or Line Balancing.

Implementing General Motors Production System and Plant Manpower Planning with production group leaders

Set the production TAKT Time based on monthly volume to ensure achieving costumer demand with standardized work implementation.

Assisting in Developing the OEE metric for tracking overall plant operating efficiency and in reducing the cycle- time of processes.

Global Certified SME for Lean Manufacturing Standardization / IE lean tools (STDS - APS – GPMC - TIP)

Involve operators in continuous improvement activities to drive ownership and accountability in processes

Participated in global industrial engineering team improving efficiency within production lines ( CT, VA%, OS

Prepare Labor cost inputs details for year Budget and LTP budget (Long term plans).

Conduct Operation Readiness for new projects (Sealer Glazing Robot & Paint Automation Project Robots)

Working with Sales/Production Planning teams in leveling Production schedule to align standardized work with customer demand and material delivery.


Reduce labor costs by $2 million through effective Line Balancing Workshops / Volume Impacts studies through time frame 2 years (2015-2017), work floor space increased by 13% through application of Kanban, and enhanced process throughput 18% by applying lean manufacturing principles.

Save $50K by leading a team in integrating visual auditing systems (Global Production Monitoring & Control) into manufacturing process to automate monitoring equipment health, product quality and Lines throughput.

Key contributor to Lean Leadership Summit, an annual corporate training event, developed key workshop content in Lean, conducted classes and workshops for all levels of the organization that save $32K outsource trainings.

Save $3K by translate interface of a global Program used in Production processes Standardization

Key Player in Plant Certification in world class Lean Manufacturing System Level3.

Develop New Global Throughput Improvement Process tool.

Decrease Safety cost by 10% using standardized work PPE man for each station.

Increase Quality matrixes efficiency with 15% by implementing ANDON system through the whole plant.

Plastics Production Section Head Feb 2014 – Jan 2015 Universal Group for Metal Industries


Apply continuous improvement methods such as lean manufacturing to enhance manufacturing system.

Investigating ways in which the latest technology could improve the productivity of the manufacturing

Develop operating instructions and equipment specifications for production activities.

Prepare reports summarizing information of Production Performance Optimization.

Setting optimum processing conditions for plastic processing machines.

Monitoring & Follow-Up the Installation of Plastic Injection Machines.

Develop best practices to improve production capacity, quality and reliability.

Investigate problems, analyze root causes and follow-up action plans. Achievements

Saving $625K by eliminating a non-required machine installation materials.

Lead a team of 30 operators and 4 Engineers in Setup 76 Plastic Injection Machine for the new Universal washing Machines Plan.

Participate in installing new washing machine assembly lines.

Participate in installing new stamping machines for sheet metals.

Production Engineer Aug 2010 – Feb 2014

BSM for Plastic Injection and Extrusion


Setting the Optimum Processing Conditions for Machines.

Manage all roles of Production Planning Section (Implementing ERP System using Excel VBA).

Prepare reports summarizing efficiency of manufacturing performance.

Conduct detailed technical analysis of production schedule, including constraints, utilization, and slack toward Program milestones; identified and presented risks and

Working with Sales/Production Planning/Purchasing teams in leveling Production schedule to align standardized work with customer demand and material delivery.

Plant Downtime Analysis using Lean manufacturing tools.

Analysis of operational issues and installation of new equipment.

Implement cost reduction initiatives while maintaining high quality standards. Achievements

Reduce Product costs by $160K through using more efficient low cost material mix.

Reduce labor costs by $30K by using man-machine charts that reduce more than 20 operators.

Save $105K by replacing Web based ERP system with Local developed using Excel VBA macros.

Fix Plastic Injection mold processing issue that save $69K

Conduct KAIZEN events (Best Suggestion Program), best ideas save $12.5K

B.Sc. in Mechanical Production Engineering (Sep 2005 - May 2010) Akhbar El-Yom Academy

Major Field: Production and Printing Technology.

GPA: 3.3 (84.61%) Very Good with Honor Degree

Project Title: The Professional English Wheel.

Project Objective: Sheet Metal rolling in automatic way with high thickness.

Project Grade: Excellent.

Certified Lean Six Sigma Black Belt (Expected Jul 2018)

Unversity : Arab Academy for science, technology & maritime transport (AAST)

Certified from: IAASS

English (IELTS trial test Scores)

Listening 6.0

Reading 6.2

Writing 6.3

Speaking 6.1

Arabic (Mother Tongue)

Listening Excellent

Reading Excellent

Writing Excellent

Speaking Excellent



ERP Excel System (Freelancing)

1. Procter & Gamble: FP IMPORTS REAL TIME TRACKING SYSTEM.(2014) 2. BSM for Stationery Manufacturing: ERP Excel System (Production-Purchasing-Cost Analysis-Maintenance-Stores) Full Modules.(2011 – 2014) 3. Universal Group: Excel Automation Solution for fitting Plastic Molds with Plastic Injection Machines.(2014)

4. Palm Hills GYM: Excel Automation Solution(Desk Customers Service).(2014) 2007 ICDL Akhbar El-Youm Academy

2009 Autodesk Inventor Professional Cairo University 2010 English Conversation Cambridge Training College Britain 2011 Plastic Injection Molding and Plastic Extrusion PTC 2012 Excel VBA Macros Self-Study

2013 Lean Manufacturing MATC training Center

2013 Quality Observation and Improvement MATC training Center 2013 Basics in Silk Screen Printing MATC training Center 2014 Safety & IH site training Universal Group

2014 Project Management Universal Group

2015 GMS (GM Global Manufacturing System) General Motors NAF 2015 Productivity Improvements General Motors International 2015 Egyptian Labor Law Top Business

2015 Budget & Cost Control Top Business

2015 Business Simulation. Brainquil

2015 Lean Manufacturing Simulation workshop. General Motors NAF 2016 Throughput Improvement Process General Motors International 2017 High Impact of Presentation Dale Carnegie

Personal Projects



• Drive For Results

• Action Oriented

• Decision Quality

• Career Ambition

• Building Effective Teams

• Conflict Management

• Directing Others

• Self-Development

• Creativity

• Problem Solving

• Developing Direct Reports

• Presentation Skills

• Priority Setting

• Work/Life Balance


Date of Birth: 18-3-1988.

Nationality: Egyptian.

Marital Status: Married – 2 children

Military Status: Exempted.


Playing Football : i played as a Professional

Soccer player in biggest egyptian clubs : 6th of

October City Club, Police Club, Zamalek Club,

and Pepsi Club.

Trying all Kinds of Sports.


Play Video Games.

Internet Researches.

All References available upon request


Personal Details/Intrests

Contact this candidate