Technical manufacturing factory manager
Resume:
Amr Shehata
Dubai, UAE • +***.********* • adox46@r.postjobfree.com
Senior Management – Manufacturing and Projects
Versatile, enterprising, resourceful Mechanical Engineer with 15+ years of rich hands-on leadership experience in the domains of manufacturing, plant operations and management, project management, installation, commissioning, operation, maintenance, overhaul and rebuild or high technology, high speed sophisticated production line equipment. Accomplished manager capable of collaborating with stakeholders, leading and motivating multinational teams and delivering all goals and objectives through effective strategizing, planning, resourcing and execution. Proactive achievement driven professional seeking a management position to utilize multifaceted competencies and deliver outstanding results, adding value to the organization.
Key Skills
Project Management
Project Engineering
Installation and Commissioning
Manufacturing
Plant Management
Maintenance Management
Technical Support
Equipment Overhaul and Rebuild
Customer Relations Management
Continuous Improvement Plans
Strategic Planning and Execution
Budget and Financial Controls
People Management
Stakeholder Relations
Teamwork and Leadership
Professional Experience
FACTORY MANAGER (March 2015 to date)
European Asian Tobacco FZE, Jebel Ali Free Zone, Dubai, UAE
Provide inspired leadership company wide.
Make high-level decisions about policy and strategy.
Report to the board of directors and keep them informed.
Develop and implement operational policies and a strategic plan.
Act as the primary spokesperson for the company.
Develop the company’s culture and overall company vision.
Help with recruiting new staff members when necessary.
Create an environment that promotes great performance and positive morale.
Oversee the company’s fiscal activity, including budgeting, reporting, and auditing.
Work with senior stakeholders, chief financial officer, chief information officer, and other executives.
Assure all legal and regulatory documents are filed and monitor compliance with laws and regulations.
Work with the executive board to determine values and mission, and plan for short- and long-term goals.
Identify and address problems and opportunities for the company.
Build alliances and partnerships with other organizations.
Oversee day-to-day operation of the company.
Full responsibility for P&L for the company.
Operation and Maintenance Manager (April 2013 to March 2015)
European Asian Tobacco FZE, Jebel Ali Free Zone, Dubai, UAE
Highlights:
Improved performance of the factory – increased production efficiency from 58% to 92%, decreased maintenance cost by 45% and reduced breakdown hours by 38%
Key Responsibilities:
Operations Management
Lead and manage day-to-day operations of the facility implementing strategies and plans to deliver production targets within agreed budgets.
Ensure operation of all manufacturing and packing lines at the highest levels of efficiency and review production schedules to maintain established product inventory levels. Control flow of products from subsidiaries to achieve overall optimum stock holdings.
Monitor and ensure that equipment status as well as operator knowledge and performance to ensure reliable, safe and efficient process operations.
Develop and administer the plant manufacturing budgets, monitor operation expenses, identify opportunities for cost reduction without reducing product quality and execute appropriate action plans.
Plan and manage mobilization and allocation of resources – manpower, equipment and materials – and ensure optimum utilization to achieve all predefined goals and targets
Contribute to development of new products aligned to market needs in close coordination with research and development and product management teams.
Support the purchase manager in all aspects of vendor development, vendor performance evaluation, improvement in supplier relations and provide on time purchase requisitions for procurement of production requirements at best prices and terms.
Maintenance Management
Lead and manage all plant maintenance activities to ensure efficient, cost effective and on time execution of maintenance jobs to deliver high levels of plant availability and reliability.
Develop, implement and update a work control system for monitoring all ongoing maintenance programs for assuring optimized, economical, safe and reliable plant operations.
Formulate and supervise execution of predictive and preventive maintenance programs to optimize performance and reliability of plant systems and equipment.
Develop and implement maintenance policies, procedures and documentation supporting safe, efficient and consistent execution of all maintenance jobs.
Engineering Support
Manage and administer the engineering support organization for delivery of high standards of technical services and support to the operations and maintenance teams.
Supervise and control all equipment modification programs assuring on time planning and execution of design, review, control, implementation and documentation of equipment design changes as per approved standard procedures.
Implement processes for monitoring equipment performance to identify variance and issues on time and execute measures to optimize performance.
Formulate and implement policies and procedures assuring delivery of engineering support for safe and efficient operations of equipment.
Continuous Improvement Programs
Develop and promote a culture of continuous improvement in the organization based on adoption of industry best practices and employee engagement.
Drive programs for identification of production constraints and streamline processes to improve efficiencies, enhance productivity and minimize waste.
Quality, Environment Health and Safety Management
Collaborate with quality personnel in monitoring product quality, tracking scrap rates, evaluating trends and implementing action plans to achieve product quality consistency as well as reduction in scrap rates.
Coordinate with the environment, health and safety (EHS) manager in ensuring EHS awareness among the manufacturing team and creating a safe and healthy work environment.
Support the building and maintenance of a superior safety and housekeeping program across the facility including initiatives for on time communications with stakeholders.
Staffing, Manpower Management and Training
Assess workforce requirements of manufacturing departments periodically and coordinate selection, hiring and training of required personnel.
Conduct scheduled performance appraisals of staff, identify training needs and provide required training and development support to build required competencies.
Deal with industrial relations including investigation and resolution of employee grievances and administration of collective bargaining agreements.
Manage all aspects of employee training and development by providing general training to employees as well as specific training to operations and maintenance personnel to build and reinforce required skills, competencies and behaviors.
Plan and organize training facilities, equipment and materials and ensure efficient and effective utilization to deliver predetermined training outcomes.
Senior Mechanical Service Engineer (December 2006 – March 2013)
G.D S.p.A., Bologna, Italy
Profile: G.D is the world’s leading supplier of high-tech machinery for cigarette making and packing, filter production, other tobacco-based and special products.
Highlights:
Executed assignments across the Middle East, Africa and Asia for installation and commissioning of high-technology high-speed machines of production lines including successful completion of protocol tests.
Managed assignments for maintenance, overhauls and rebuild of old machines at customer sites to restore them to best performance and passed protocol tests.
Projects:
Installation and commissioning of complete cigarette production line
British American Tobacco factory, Ibadan, Nigeria
Eastern Company, Giza, Egypt
Japan Tobacco International (JTI) factory, Izmir, Turkey – assistance
Company Monus, Inđija, Serbia – mechanical equipment
Japan Tobacco International (JTI), Jordan
Eastern Company factory, 6th of October City, Egypt – 3 complete lines
British American Tobacco (BAT) factory, 6th of October City, Egypt
STAEM plant in Algeria. Received a certificate from Philip Morris International – 2 complete lines
Gold Leaf factory, Johannesburg South Africa.
Inspection, rebuild and improvement in production line performance of complete production lines
A client in Egypt – assisted an experienced engineer
Japan Tobacco International (JTI), Jordan
Japan Tobacco International (JTI), Tanzania
British American Tobacco (BAT) factory, Oran, Algeria
Overhaul and complete rebuild of production lines
Shenzhen Cigarettes Factory Co, China
Eastern Company factory, 6th of October City, Egypt
Key Responsibilities:
Worked with project engineering team in testing and troubleshooting systems and mechanical hardware of production lines and implemented approved design modifications as per the company’s change control procedures.
Participated in project risk assessments and project kick-off meetings ensuring availability of all technical deliverables for the project.
Coordinated with the design engineering team in designing all system logics and worked with project engineering to review and ensure that all mechanical drawings adhered to project requirements.
Prepared, reviewed and implemented written commissioning procedures including site acceptance test procedures for various systems and equipment.
Modified the project document system as per requirements and communicated changes to the project engineering team as per approved change control procedures.
Prepared training materials for various systems and technologies of production lines provided training to customer personnel on safe and efficient operation of the production line and delivered standard service products for each technology.
Traveled to customer sites both in Egypt and in international locations for installation and commissioning as well as service of production lines as per customer requirements.
Managed service assignments, independently resolving complex problems and taking sound technical decisions to meet customer requirements while protecting the company’s commercial interests.
Built and managed good relations with customers through proactive and effective service delivery and support and prompt issue resolution.
Participated in project wash-up meetings contributing to resolution of remaining problems at end of the project for smooth handover to the customer.
Ensured on time and accurate preparation of all business related documents and reports including commissioning reports, time tracking reports, site visit reports and expense reports as per company procedures.
Trained engineers of customers and company distributors on maintenance of various production line machines and produced required service manuals.
Determined requirements of spare parts of the company’s installed base in Egypt and coordinated procurement from the company HO in Bologna Italy.
Monitored performance of company production lines at customer sites in Egypt and produced technical reports for the customer as well as for G.D Bologna.
Ensured compliance with all statutory requirements as well as company policies and procedures related health, safety and prevention of workplace hazards.
Previous Assignments
Mechanical Maintenance Engineer, Universal Company of Crystal Products (Asfour Crystal) – a leading firm in the domain of crystal manufacturing for applications globally, Cairo, Egypt, December 2004 to December 2006
Education
B.Sc. – Mechanical Engineering, Helwan University – Egypt, Cairo (May 2004)
MBA – Harvard Business School (working on it )
Professional Development
TRAINING COURSES AND WORKSHOPS:
Training with technical staff of the company for construction of plants for chemicals and explosives industries, Josef Meissner GmbH & Co, Germany
Training, Universal Company for Cellulose Products (EGYCELL), Egypt
Technical seminar on selection, maintenance, mounting and dismounting, lubrication and grease rates for rolling bearings, NKE Bearings, Austria
3-month training on cigarette making and packing machines – details of machines, use of high-tech tools and instruments for checking the machines, use of PLC for detecting problems and troubleshooting of problems, execution of heavy mechanical works and means for improving machine performance, G.D S.p.A. Bologna Italy
2-month training on deep maintenance and overhaul of medium speed machines (12,000 cpm), GD Turkey, Izmir Turkey
Personal Details
Nationality: Egypt ~ Date of Birth: 25 May 1980 ~ Marital Status: Married ~ Hobbies and Interests: Reading, Drawing, Listen to Music ~ Languages: English, Arabic ~ Software: Microsoft Windows, Microsoft Office – Word, Excel, PowerPoint, Access, CMMS software
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