ALEX NAGHIBI

Production/Operations Manager

416-***-**** ad2pyl@r.postjobfree.com www.linkedin.com/in/alexnaghibi

QUALIFICATIONS AND SKILLS SUMMARY

I have over 15 years of progressive experience at managing production (material, workforce, customer demand, equipment, project, and outcome performance), quality, safety, delivery, environmental concerns, cost control, budgeting, technical sales, and customer service. Always ensuring practices are in alignment with company’s vision and KPIs in the above-mentioned areas.

Solid track record of leading process improvement projects in support of continuous improvement plans

Proven track record of achievement; 2 major new plant start-ups and commissioning operations

Excellent verifiable strengths in root cause failure analysis and troubleshooting.

Well-practiced in Lean Manufacturing, SMED, Kaizen, Six Sigma, 5S, ISO 9001, ISO TS/16949, 14001, and GMP

Successful expertise of production skills including inventory management, budgeting, reporting, environmental compliance reviews, quality improvement, safety, scheduling, and maintenance

Providing advanced leadership skills to department employees by directing, coaching, supporting, and delegating as the situation requires

Hands on experience in developing and maintaining technically advanced and safety conscious teams to achieve plant targets and organizational goals

Collaborative leader with customer service oriented teams trained to identify and remedy issues

MAJOR ACCOMPLISHMENTS

Increased productivity in spray head and spin flash dryer department by %5 to %10 – DCC

Increased productivity in compounding department over %25, using the same resources utilizing lean, 5S, and six-sigma tools – Cosmetica Laboratories

Increased productivity of the various packaging lines from %25 to 33%, using the same resources utilizing lean, 5S, and six-sigma tools – Cosmetica Laboratories

Reduced quality related issues of all types by %20-%25, utilizing training methods, PDCA techniques (Plan, Do, Check, and Action), equipment and tooling improvement – Cosmetica Laboratories

Successfully participated in cost saving projects and saved over 30K average on a monthly base which means 8K more than the target – Cosmetica Laboratories

Lead operations manager responsible for commissioning operations and start-up of 2 new plants – Normerica & BCQ

Achieved maximum daily production goals which led to an approximate 5% to 10% increase in production while maintaining minimum waste and least system failures and downtimes – Normerica

Leader of a successful team, which designed and applied an award winning system for waste reduction with lowest expense, saving the company more than 1 million dollars per year – Pirelli

Designed, launched, and developed a new innovative product (tire) as a key team member, this could lead to a company profit increase of five million dollars per year– Pirelli

Surpassed team sales targets as a successful manager and achieved maximum targets for 2 consecutive years – Rona

EMPLOYMENT HISTORY

Plant Supervisor – Dominion Colour Corporation (DCC) Jan. 2018-Dec 2022

Operations Manager HP Unit – Cosmetica Laboratories Inc. 2016-2017

Production Manager – Normerica Inc. / Northdown Industries Inc. 2014-2016

Department Manager – Rona 2012-2014

Production Supervisor – BCQ Chemical Group 2010-2012

Plant Shift Manager – Pirelli Tires 2004-2010

Strategic Marketing and Technical Sales – Belzona Polymeric limited 2001-2003

PROFESSIONAL EXPERIENCE

DCC:

Managing and directing shifts of production operators who are members of Teamsters Local 1979, and who are partly managed by the terms of the Collective Agreement entered into between the Company and its employees.

Schedule weekly, and monthly production for four production lines in a custom manufacturing environment

Administration of disciplinary measures to team members, in accordance with the terms of the collective agreement in the event of poor performance, such measures may include counseling, warnings, and/or suspensions/Terminations.

Responsible for safety, production, inventory, maintenance, and quality throughout the plant operations

Create work orders, batch sheets, log sheets, bill of material, etc.

Ensuring all team members are trained and adequate backup is available to operate all functions

Responsible for the recognition of good performance and to make recommendations regarding the recognition process

Conduct safety and environmental inspections

Conducting health and safety meetings

Managing the overall attendance and timekeeping for all team members

Conducting health and safety training to team members as may be required from time to time

Responsible to work with R&D department for product development/launch

Responsible to work with process department for safe disposal of hazardous material

Responsible to create and present statistical reports, continuous improvement recommendations as well as budget recommendation and discussions

Cosmetica Laboratories:

Responsible for 200 employees across 3 shifts and over 10 direct reports in a custom manufacturing environment

Reviewed all infraction and process non-conformances, initiated investigations, and implemented preventive/corrective action to resolve safety issues successfully in a timely manner

Responsible and accountable to provide leadership for complying with OHSA, Company policies, and Safe Work Instructions to ensure the adherence consistently and effectively

Developed operational teams in support of company growth initiatives through coaching, mentoring, training, and performance management, always provided with clarity, fair management.

Provided strong leadership to the teams that fostered personal development, interaction, participation that could increase the level of team work and engagement

Developed systems and metrics to measure and evaluate productivity, individual performance, and contribution on an on-going basis

Ensured practices maintain professional and all activities comply with all regulatory requirements, GMP, safety, and company policies

Acted as a specialized manufacturing resource to senior management team and board of directors and supported the resolution process of complex issues

Provided recommendations to the next level of management regarding procedural and organizational changes and improvements as per request

Supported company’s commitment to continuous improvement and cost efficiency through identifying and implementing effective CI projects

Reviewed flow of materials, identified areas of waste, planned accordingly, and eliminated unwanted waste.

Monitored and improved key operational metrics for Safety, Quality, Efficiency, Cost, and on time delivery

Reviewed and controlled departmental budgets and efficiently met operational targets

Monitored functional area of growth anticipated and obtained resources appropriately by analyzing sales forecasts and participating in product development activities

Investigated product quality issues and product non-conformance issues in a timely manner and ensured corrective and preventive actions in place

Monitored customer feedback through various channels and closed any gaps in performance

Normerica as the Production Manager:

Managed, coached, and trained senior supervisors and 30-50 employees in a fast-paced production environment while managing new process designs, installations, and startup projects.

Identified and resolved operational, manufacturing and maintenance issues within deadlines.

Planned workflow, managed multiple priorities, and met production targets while consistently reduced downtime.

Developed new procedures/processes and improved production accuracy.

Set up health and safety audit procedures and improved safety efficiencies.

Utilized lean manufacturing, process improvement techniques and maximized cost efficiency across the plant.

Established and maintained acceptable quality levels for all assigned products.

Efficiently set and controlled operational budgets.

--- Successfully managed and delivered this $3.3 million project simultaneously as the Project Manager ---

Designed, planned, coordinated with consulting engineering firms, and purchased new equipment from EU and US for a brand new product.

Coordinated with manufacturers on specifications and deliveries, set up the production floor, managed all contractors and the workshop during installation in a clean and safe environment complying with all the necessary requirements by the ministries involved in various stages of the project, and installed the new equipment in a timely fashion as planned.

Managed pre-commissioning and commissioning, implemented all the necessary changes to validate commissioning and successfully performed start up.

Assisted the legal team and the patent writer to finalize and fine-tune the patent.

Managed trials for product development in the lab and production environment, created recipes, fine-tuned quality system, created standard operation procedures, SOPs, SSOPs, Documentation for GMP audits, etc.

Interviewed, hired new operators, trained them, and troubleshoot the new system to optimize production.

Designed a highly efficient Preventive Maintenance program complying with manufactures concerns and plant precautions, fine-tuned frequencies during operations. Created critical parts list and stock, this reduced the downtime.

Previous Positions:

Executed continual improvement projects utilizing PDCA cycles (Plan-Do-Check-Action) that substantially reduced waste across the production line, subsequently yielding cost savings of over 1 million dollars annually, could also led to elimination of some environmental impacts and reduced the impact level of some significant aspects.

Key member of the Quality Assurance team (TQM) that helped the plant to achieve six consecutive years of successful recertification in ISO 9001, ISO TS/16949, and 14001 post the external audits.

Supervised several teams of over 200 associates during each shift, Provided the teams with clarity, fair management, periodic work assessments, and performance reviews that made them highly motivated successful teams in a healthy work environment, and achieved management goals and expectations.

Created, modified, and performed periodic customized machinery maintenance plans resulting in over 10% reduction in machinery failures and downtimes, thus increasing output and enhancing production.

Identified, provided analysis, suggestions to senior management on strategies, plans, processes, tools, techniques, and human resources to generate quality products, environment and enhance stakeholders investments.

Liaised and negotiated with customers and staff from other sectors to discuss issues with the impact on investments interests and provided Issues management.

EDUCATION AND TRAINING

Bachelor of Science in Chemical Engineering---Degree (4 Years Program Accredited by PEO and ICAS)

Kaizen, 5S, Six Sigma, Design of Experiments, Lean Manufacturing, and Quality Techniques

ISO 9001 Internal Audit, ISO TS/16949 Internal Audit, ISO 14001 Internal Audit

Calendering Technology, Extrusion Technology, Mixing of rubbers

Marketing Techniques, Sales and Customer Service, Issues Management

Expert at these large scale machineries: duplex extruders, rubber calenders, mixers, fluid bed dryers, Packaging lines

Advanced computer skills: Visual, Microsoft Office, Word, Excel, PowerPoint, Visio, Access, Outlook, Citrix, Internet

PROFESSIONAL MEMBERSHIPS

Former Member of Professional Engineers Ontario, EIT (PEO)

Former Member of Ontario Society of Professional Engineers (OSPE)

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