Program manager, Quality Manager, Metallurgist, Professional Engineer

Kamal El -Rassi, P.Eng. ***** Teakwood Dr., Monroe, MI, 48161

Tel : 734-***-**** *****.*******@*****.***

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Manager Quality Assurance

Scrap-Melting-Rolling-Chemlab-Metlab-Non Destructive Testing-Customer Customer Relations and Product Development (PPAP, FMEA, APQP for SBQ & ZF grades) Meltshop General Forman and leader with more than 17 years experience in Canada and the US with Cargill North Star Steel, Atlas Specialty Steel and Gerdau. Hands on experience dealing with contract and labor union issues, floor experience commissioning large capital projects inside melting and rolling facilities. Meltshop production experience in special bar quality, automotive and aircraft blooms/billets/bars, ZF grades, stainless 300, 400, 174, VAR, and tool steels. Cross department project implementation and team facilitation to resolve conflicts and enhance team dynamics, solve problems and find root cause. Quality and MeltShop department functional strengths include recruitment, team building, succession planning, performance management, coaching, process management and safety programs implementation. Working knowledge of process variables, ZF/VDA/QR83, Six Sigma, TS16949 & ISO14001. Large Capital Projects Hands On Experience, Commissioning Engineer

§ Assisted in Danieli rolling mill and new reheat furnace commissioning, $80 million

§ Danieli 4 Strand Continuous Caster in Gerdau St. Paul, MN 2014

§ Danieli Twin Tank Degasser in Gerdau Monroe-2014 $40 million

§ Danieli Ladle Furnace Upgrade in Gerdau Monroe-2014

§ Praxair Electric Arc Furnace Burner Installation in Gerdau Monroe-2014

§ Danieli 4 Strand Continuous Caster in Gerdau Monroe-2012 $40 million

§ Danieli 240/65/30 ton Hot Ladle Crane in Gerdau Monroe -2012 $5 million

§ New Mold Shop Facility (Gerdau Whitby-2007 and Gerdau Monroe-2012)

§ Brucker Fully Robotic Chemlab facility in Whitby-2011, in Gerdau Monroe 2014

§ Meltshop Execution System (QMOS/MES) at Gerdau Whitby in 2010, Gerdau Monroe 2014/15

§ Concast 5 Strand Continuous Caster in Gerdau Whitby-2007 $30 million

§ Team building and benchmarking activities experience with Badische Stahl 2006-2014

§ Plastic injection equipment installation & automation (Tier I supplier to GM)- WEGU 2004 UNIVERSITY EDUCATION, PROFESSIONAL ENGINEER ONTARIO (P.ENG.)

• Metallurgist

Masters of Applied Science, Metallurgy & Materials Eng. – 1999 University of Toronto

• Chemical Engineer

Bachelor of Applied Science, Chemical Engineering – 1997 University of Toronto

• Financial Accounting - Wharton University of Pennsylvania 2013-2014

• Dale Carnegie 7 Weeks Leadership Training - 2013 - Novi, MI

• Engineering Management Degree – 2002 Kennedy Western University, USA Kamal El -Rassi, P.Eng. 15055 Teakwood Dr., Monroe, MI, 48161 Tel : 734-***-**** *****.*******@*****.***

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GERDAU MONROE, Monroe, Michigan, USA [2014 - current] MANAGER QUALITY ASSURANCE

§ 25 UAW personnel, 6 salaried exempt supervisors, 3 non-exempt salaried, 12 NDT tech’s, one management associates, one ISO and TS coordinator

§ Manage Chemlab, Metlab, Non Destructive Testing, Customer Relations and Product Development

§ Respond to customer complaints and requirements GERDAU MONROE, Monroe, Michigan, USA [2011 - 2014] GENERAL FORMAN-METLSHOP

§ Managed the hourly workforce, 120 UAW personnel

§ Meltshop to run safely, efficient and effective (Safety - Quality - Production)

§ Increase productivity and cost control

§ Respond to customer complaints and requirements

§ Ensure quality and delivery expectations are met

§ Recognize safety as a key initiative

§ Foster culture of continuous improvement, teamwork and trust

§ Twin Tank Vacuum Degasser and Ladle Furnace Process Commissioning

§ Danieli 4 strand Bloom Caster Commissioning (152mm2, 210mm2), operators training, classroom/benchmark visits BSE, spare parts program

§ Electric Arc Furnace Chemical energy balance, reduce power on by 5 minutes

§ Ladle Refining Station flux and slag additions to improve desulfurization, slag control

§ Design and implement online reports for meltshop performance

§ Failure analysis and team leadership meetings, meeting facilitation, root cause GERDAU AMERISTEEL, Whitby, Ontario, Canada [2005 - 2011] CASTER MANAGER - MANAGING AND TEAM LEADERSHIP

§ Metallurgist & Facilitator: the casting area has a total of 20 hourly employees /union. My role is to provide technical help, training, communication, process improvement trials, kaizen, 5S, floor housekeeping audits, equipment upgrade and safety initiatives, etc.

§ Lead Process Engineer for a new 5 strand Concast Caster Installation and Commissioning Aug - Sep 2007 (130x130, 127x187, 152x254 mm2)

§ Billet lab and Chemistry lab supervisor in charge of all testing and OES maintenance

§ Built a billet laboratory for steel analysis and testing macros and electrolytic etching

§ Built a new mold shop facility for the melt shop to condition and rebuild molds

§ Shift Manager – supervise the melt shop floor during vacation periods and critical upgrades to help operations succeed (20 hourly employees, scrap, melting, refining and casting)

§ Direct supervisor for two hourly employees responsible for mold shop operation /union

§ Safety in Action Leadership activities, daily meetings/Safety Hour and JHSC updates

§ Quality assurance of all billet production (130 x 130, 127 x 187, 152 x 254 mm2) Kamal El -Rassi, P.Eng. 15055 Teakwood Dr., Monroe, MI, 48161 Tel : 734-***-**** *****.*******@*****.***

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WEGU CANADA INC., Whitby, Ontario, Canada [2004 – 2005] SENIOR ENGINEERING MANAGER (TIER I, II RUBBER & PLASTICS AUTOMOTIVE PARTS)

§ 5 engineers, 2 tool makers

§ Managed department budget and 5 engineers workload ($5 M projects) and all tool room activities

§ Coordinated and achieved environmental ISO14001 accreditation in 1 year

§ Improved quality index by revamping the Advanced Product Quality Planning and FMEA process

§ Automated the pressure relief valve robotic production line and reduced labor by 75% in six months ATLAS SPECIALTY STEELS, Welland, Ontario, Canada [2002 – 2004] CHIEF CHEMIST - METALLURGICAL AND CHEMISTRY LABORATORY SUPERVISOR

§ Supervised (42 employees-UAW; 30 metlab and 12 chemtechs)

§ Managed laboratory activities (NADCAP, ISO17025, ISO9001, A2La)

§ Responsible for laboratory process and equipment including X-ray fluorescence, optical emission, induction couple plasma, slag analysis, combustion carbon, sulfur, hydrogen, nitrogen and oxygen

§ Managed all metallurgist duties and special project assignments (low alloy, stainless & nickel steel, VAR steel, tool steel)

§ Purchased and Commissioned a thermo instrument optical emission spectrometer ARL OE4460 NORTH STAR STEEL- Cargill, Monroe, Michigan, USA [1998 – 2002] MANAGER METALLURGICAL LABORATORY, 2002

§ 15 metlab technicians UAW, 2 non-exempt staff

§ Managed metallurgical laboratory (15 employees-UAW) and coordinated multi-process projects

§ Conducted mechanical testing (tensile, hardness, jominy, impact) on all rolled products

§ Conducted complete Failure Analysis studies using Scanning Electric Microscope method

§ Performed monthly ISO9001 & QS9002 quality assurance department audits

§ Reduced order release time by 40%

ROLLING MILL PROCESS METALLURGIST, 2001

§ Managed projects for strategic customers to improve physical properties and overall quality

§ Chaired surface issues meetings and Process Capability Studies for the rolling mill

§ Implemented controlled rolling and thermo-mechanical rolling techniques in rolling mill process

§ Championed the Failure Mode Effect Analysis and Gage R&R plant capability studies MELT SHOP PROCESS METALLURGIST, 1998-2000

§ Improved melting & ladle refining process to modify inclusions and control slag chemistry

§ Designed, developed, and implemented a central database for entire plant operation to document all heats produced and maintain audit trail of all production work since 1998 CANADIAN ARMED FORCES – Toronto, Canada [1991 – 2005] FIELD ENGINEER – 2ND FIELD ENGINEER REGIMENT

§ Winter warfare, engineer duties, arms, soldier life, etc

§ Top candidate in several of the courses taken across Canada INTERESTS

Running, Yoga, P90X, Abs & Back fitness, martial arts Gyoshi Karate-Purple Stripe belt, volley ball, chess, tutoring, swimming, reading widely, and computer modeling in chemical engineering-thermodynamics- differential equations and heat transfer.

REFERENCES AVAILABLE ON REQUEST

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