Quality Management

Business Excellence Facilitator

(CSSBB, QMS, OHSAS, EMS & MP Auditor, BCE Assessor, BE Assessor)

Choosing Quality as a career was a bold choice from my part, relying

on my passion for the field, given that many organizations do not fully

support that field, and giving more focus to basic Technical activities of

production and maintenance. However, as a genuine believer in the roles of

Quality Engineers and Organizational Excellence Facilitators, I have made

it my mission to best utilize my knowledge in Business Excellence/

Manufacturing Excellence frameworks, Six Sigma, TPM, and TQM Methods.

In my current position in Birlacril, I just grasped the low hanging

fruits by simple techniques, Standardized work and Heijunka revealed extra

manpower, which reduction saved USD 46,800.0 per annum savings. Also

institutionalizing Employee Engagement Schemes for Quality Circles resulted

in savings more than USD 119,500.0 per annum savings. Linking Solvent

impurities to quality defects through COPQ has revealed a huge area for

improvement in solvent filtration process and control on polymerization

reaction. A Six Sigma project snatched that fruit resulting in USD

845,000.0 per annum savings. While 18 other project resulted in cumulative

savings USD 359,084.0 per annum. Saving 600 sec in each start up by just

video tapping and then SMED analysis has saved more than USD 30,000 per

annum. To start RCM initiative, without the cost of the software, I've made

a Reliability Calculation Tool, saving USD 22,817 per annum. Decreasing

Lead time in Textile resulted in USD 876,000 per annum.

Within five years I achieved total saving more than USD 2,309,201 per

annum.

Professional Strength and Scope

Business Excellence Manufacturing Excellence World Class

Manufacturing

Business Excellence Assessment Business Process Maturity Audit

Basic Condition Evaluation

Strategic planning Total Quality Management

Employees Engagement

World Class Maintenance Total Productive Maintenance

Lean Manufacturing

Maintenance Audit Reliability Centered Maintenance

Lean Coaching Experience

Continuous improvement Integrated Management System Supply

Chain Control Audit

International Experience

Professional Experience

Business Excellence Facilitator, Since 2009

Alexandria Fiber Co. SAE

- Unit of Aditya Birla Group, an Indian conglomerate of USD 40 Billion.

- Polymerization based Chemical Plant, and a Textiles Plant.

- Birlacril Business: the 5th largest Acrylic Fiber manufacturer in the

world. It consists of two manufacturing units; Thailand Acrylic Fibers

Co. ltd, and Alexandria Fiber Co. SAE.

Key Tangible Achievements

V Micro-Management Excellence, Time and Motion Studies, USD 46,800.0 per

annum savings

V Employee Engagement Schemes (Quality Circles), USD 119,500.0 per annum

savings

V Cost of Poor Quality and Critical Processes Capability Elevation, USD

845,000.0 per annum savings.

V SMED, Fast Change Over, USD 30,000 per annum savings.

V RCM, Reliability Calculation Tool, USD 22,817 per annum savings.

V Layout study, Material Flow, Lead Time Decrease, USD 876,000 per annum

savings.

Programs & Projects

* Strategic Improvement Projects:

. 4 Strategic Projects; Chartered with CEO, DMAIC Methodology, 2012

. 15 Strategic Projects; Chartered with CEO, DMAIC Methodology, 2013

* Quality Circles Stories:

. 19 QC Projects; 12 Steps Methodology, 2012

. 71 QC Projects; 7 Steps Methodology, 2013

Audits & Assessments

* Governance Risk Controls Audit- Supply Chain Management

. Alexandria Fiber Co. SAE, Alexandria, Egypt

* Business Process Maturity Audit,

. Alexandria Fiber Co. SAE, Alexandria, Egypt

* Business Excellence Assessment:

. Indo-Gulf Fertilizers Business, at Jagdishpur, near Lucknow in UP,

India (ABG BE Framework)

. Birlacril Business, Bangkok &Saraburi, Thailand (TQM 14 Elements

against ABG BE Framework)

* Quality Management System compliance with ISO 9001:2008

. Alexandria Fiber Co. SAE, Alexandria, Egypt (Full System Audit)

* Basic Condition Evaluations:

. Thailand Acrylic Fiber Co. Ltd., Saraburi, Thailand

. Alexandria Fiber Co. SAE, Alexandria, Egypt (Full Cycle)

* Maintenance Audit:

. Alexandria Fiber Co. SAE, Alexandria, Egypt (Full Cycle)

* 5S Audits

. Thailand Acrylic Fiber Co. Ltd., Saraburi, Thailand

. Alexandria Fiber Co. SAE, Alexandria, Egypt (Full Cycle)

Overseas Assignments

1- Thai Acrylic Fibre Co. ltd (Unit of Aditya Birla Group), March & April

2013

The most profitable Acrylic Fiber manufacturer; they've obtained more

than 45 International Award out of which are;

. TPM Excellence Award First Category, Japan Institute of Plant

Maintenance, JIPM, 2001

. TPM Consistent Commitment Award First Category, JIPM, 2003

. Special Award For TPM Achievement, JIPM, 2005

. Deming Application Prize for TQM, Japanese Union of Scientists &

Engineers, JUSE, 2001

. Japan Quality Medal, The highest Quality Recognition in the

World, "Deming Grand Prize", JUSE, 2005

Assignment:

- Business Excellence Assessors Training.

- BE Assessment of Birlacril Business.

- Understand Systems in TAF, and study replica-ability in AFCO.

2- Indo-Gulf Fertilizers (Unit of Aditya Birla Group), September 2013

The most energy efficient vintage Ammonia & Urea plant worldwide; they

have obtained more than 26 International Award out of which are;

. TPM Excellence Award First Category, Japan Institute of Plant

Maintenance, JIPM, 2000& 2002

. Best Managed Company, M/s Forbes Global, USA,2002&2003

. International Asia Pacific Quality Award, by Asia Pacific

Quality Organization, Mexico, 2003

. Deming Application Prize for TQM, Japanese Union of Scientists &

Engineers, JUSE,2004

. ABG Chairman WCM Gold Award, 2004

. India Manufacturing Excellence Award, 2012

. Platinum Award in Process Sector by The Economic Times and Frost

& Sullivan, 2012

Assignment:

- BE Assessment of IGF Business for the Chairman Excellence Award.

Certifications

International Registration of Certified Auditors, IRCA, CQI;

Certified Quality Management System: 2008 P-Auditor, 2013

Certified Occupational Health & Safety Assessment Series: 2007 P-

Auditor, 2013

Certified Environment Management System: 2004 P-Auditor, 2014

Aditya Birla Group, Corporate WCM Cell;

Certified BE Assessor, ABG Business Excellence Framework (similar to

EFQM), 2013

Certified Basic Condition Assessor, ABG BCE Standard, 2012

Certified Maintenance Protocol Auditor, ABG MAP, 2012

Certified Reliability Specialist, ABG CWCM Cell, 2012

American Society for Quality: ASQ

Certified Six Sigma Green Belt: CSSGB (Certification Number 6516),

2011

Gyanodaya Virtual Campus;

Certified Six Sigma Black Belt, 2011

Training Courses

Gyanodaya Virtual Campus;

PM Essentials: Introduction to Project management, 2012

Strategic Management: Analysis and Choice, 2011

OGS; Oil & Gas Skills, Egyptian Ministry of Petroleum Affiliate;

Rotating Machineries, 2011

Water Treatment and Water Injection, 2010

HAZOP Principles, 2009

National Association of Safety Professionals- NASP;

NASP Safety Management Diploma, 2010

OSHA Outreach Training Program;

OSHA General Industry Safety & Health (29 CFR 1910), 2010

OSHA Construction Industry Safety & Health (29 CFR 1926), 2010

Shop Floor Exposure

IGF (Indo-Gulf Fertilizers Ltd.)

TAF (THAILAND ACRYLIC FIBER Co. Ltd.)

SIDPEC (SIDIKERIR PETROCHEMICALS Co.)

EPC (EGYPTIAN PETROCHEMICALS Co.)

AMOC (ALEXANDRIA METAL OILS Co.)

AMRIYA PHARM (AMRIYA PHARMACEUTICAL INDUSTRIES)

ASSC (SOLVAY ALEXANDRIA SODIUM CARBONATE Co.)

Skills

Education

Msc QM, WCM & Manufacturing Excellence, Arab Academy for Science and

Technology, 2014

PGD, Petrochemicals Industries, Alexandria University, 2010

B. Sc, Chemistry/Biochemistry Major, Alexandria University, 2007

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