Mohamed Abbas

Lean Manager

+201*********

Hadaiq El-Qubbah

https://www.linkedin.com/in/mohamed-

abbas-5b82035b/

adpyb1@r.postjobfree.com

Summary:

Experienced Lean Manager with a demonstrated history of working in the FMCG, Automotive, Crystal, Electrical and Electronic industries. Skilled in shop floor management, effective problem solving, Continuous Improvement culture, KAIZEN & Lean manufacturing applications

Work Experience:

Lesaffre Egypt “Food Industry – 1Y experience”

Drive & Lead the Lean function with coordination of regional team for the first time at Lesaffre Egypt

Develop and Lead the Continuous Improvement projects & activities designed to improve performance and contribute to a wider understanding of lean management perspective

Lead the Daily Gemba Walks at VPM Boards in order to coach & identify the daily problem-solving activities and developing the monthly KAIZEN events / Calendar

Develop and Execute annual Lean Roadmap in coordination with management and regional team

Ensure that CI Projects comply with factory management team strategy and cooperate with key business stakeholders in deploying new project initiatives

Organize and lead training programs to provide a better understanding of concepts such as lean management, operational excellence & continuous improvement by using the different tools (OEE, AM, TPM, VSM, Visual Management, 5S, Problem Solving, Waste Elimination, etc.)

Ensure that Health & Safety Requirements are met while implementing lean projects

Contribute to the development and implementation of best practice lean vision, strategy, policies, processes and procedures to improve the operational performance

Contribute to new business initiatives and projects and communicate the impact of these initiatives

Develop and publish business improvement process documentation to reflect best practices

Perform Root Cause Analysis to resolve problems in the factory and supportive functions

Identify business improvement opportunities for the factory, develops projects & action plans, and align with the management team and concerned parties

Recommend improvement solutions for cost optimization without compromising quality standards

Follow technology and digital changes that may affect Lean activities

Share the best practice examples within the region and/or the group to create awareness

Develop Annual VSM Event for selected Areas to enhance the Lean tools Lean Manager

Aug 2021 – Present

General Motors Egypt “Automotive Industry – 8Y experience” Global Lean Manufacturing System Lead

July 2020 – July 2021

Lead and coach GM Egypt to apply and implement GM Global Lean Manufacturing System

Support and conduct calibrations / audits to identify the level of implementations of the GMS and responsible to identify the Gap and develop with principles’ SMEs the detailed action plan

Lead and coach the implementation of the Built-In-Quality system “5 Lean Pillars”

Lead and tracking meetings for the GMS implementation with leadership team and SMEs

Coach and train hourly & salaried teams for better understanding of GMS elements & tools

Conduct XMB (Lean Simulation) and SWE (Simulated Working Environment) Trainings for both Salaried and hourly as per the annual plan

Develop and conduct GMS internal calibration/Audit process at least once a year

Support and facilitate GMS external calibration process, if required

Participate in the GMS SMEs monthly conference calls

Support GM regional team to develop new Lean operating tools

Effective participation in the planned mega KAIZEN Events promoting the waste elimination culture

Track and report the GMS Monthly scorecard data internally and externally (GMI) including the mandatory metrics for BIQ IV

Continuously develop improvement in designs & processes using lean manufacturing concepts

Support the flawless launch for new programs and projects

Lead CIP Program (Submissions, Monthly Recognition, Quarterly & annually celebrations) at GM Egypt to improve the SPQRCE performance

Lead the continuous improvement process on shop floor to improve the SPQECE performance

Support in developing the annually MFG Business Plan (SPQRCE – BPD) General Assembly Production Lead

Oct 2016 – June 2020

Responsible for pickup & Passenger assembly lines, reporting to me 3 Group leaders, 17 Team Leaders & 200 Team members with total HC 220 reporting to me

Understand the S&IH hazards and significant risks of the working area and manage them with the hierarchy of health and safety controls with the required mitigation plans

Conduct effective Safety Observations Tours as required

Supervising and motivating a team of workers

Reviewing and evaluating the performance of subordinates

Ensuring that the production is cost effective, by applying the GMS “Lean” tools

Making sure those products are produced on time and are of good quality

Working out the human and material resources needed

Monitoring product standards and implementing quality-control programs

Implement cost reduction initiatives while maintaining high quality standards

Investigate problems, analyze root causes and drive for solutions

Identifying training needs and provide it to TMs to accomplish the production goals

Working on improving the productivity, HPU, VAA%, HC optimization, Labor Optimization, the Work Loading% (Sigma CT) and analyze the weekly / monthly DT to improve the throughput

Enhance the continuous improvement in SQPRCE & waste elimination culture Lean & Continuous Improvement Engineer

Dec 2013 – Sep 2016

Identify the level of implementations of the GM-GMS (Performance Gap Analysis)

Coach workers & employees for better understanding of GM-GMS elements

Conduct XMB “Lean Simulation program” Training for MFG Salaried and Hourly to simulate the manufacturing system and use the best GMS tools in daily operations

Support and facilitate GM-GMS internal calibration process at least once a year

Participate in the GM-GMS coordinators monthly conference calls

Support GM regional team to develop new Lean operating tools and develop the 5S Manual

Track and report the MFG monthly KPIs data internally and externally

Continuously develop improvement in designs & processes using lean manufacturing concepts, VSM and KAIZEN Events

Support the plant in the new products / programs Launch as Operation Readiness Lead

Develop and the quarterly plant productivity workbook

Set and communicate the annual productivity targets and initiatives to shop managers

Conduct Line balance and 5S workshops to improve the productivity and working conditions Stretch

Assignments

Regional XMB (Lean Simulation) Trainer

KAIZEN Coach

Internal XMB (Lean Simulation) Trainer & New Products MFG Operation Readiness Lead

GMS People Involvement SME & Calibrator / Auditor

2020 – 2021

2019 – 2021

2015 – 2021

2014 – 2021

Achievements:

Conduct 2 XMB (Lean Simulation) Training waves for GM North America Executives at MI, USA, 2 training waves at GM South Africa, 7 training waves for salaried, 12 training waves for hourly and 1 training wave for GM Lead program from different departments at GM Egypt

Achieve GMS BIQIV with 90% score and Zero absolutes, PI highest score 94%

Conduct 16 KAIZEN Events with 16 HC reduction around the total plant

Productivity Improvement 6% in Pickup production lines

Overspeed Improvement from 7.5% to 5% meeting the global benchmarking

Productivity Improvement by 7% in Pickup production lines reflected at OpEx project with $830K for two years savings

Achieve GMS BIQIII with 86% score and Zero absolutes, PI highest score 94% 2015 – 2020

2019

2018

2016

Asfour Crystal International “Process Industry – 0.5Y experience” Industrial Engineer

June 2013 – Dec 2013

Responsible for APS (Asfour Production System) manual keys and implementation of every key across all the plant working areas

Develop the Process Mapping & VSM eliminating the waste in the whole stream

Using RAS (Random Activity Sampling) & Time Study for collecting and analyzing the data to find the bottleneck and making the proper Throughput improvements

Develop Environmental studies for shop floor to make better environment working conditions

Searching for the best Ergonomics engineering solutions and controls for shop floor

Implement 5S techniques from scratch in different working areas

Develop the required SOP (Standard operating procedure) of every process

Using Spaghetti diagram to reduce the walking time in and between different production areas TEPCO Egypt “Electrical Assembly Industry – 1Y experience” Continuous Improvement Engineer

Sep 2012 – June 2013

Implement different Lean Manufacturing tools and methodologies

Improve plant’s layout design for LBS line and LV chassis assembly lines

Develop and Evaluate the KPIs for LBS assembly line monthly (Production, Quality, Delivery)

Responsible for all the plant’s industrial needs starting from the design to the manufacturing process

Conduct KAIZEN event quarterly searching for the best and innovative ideas to improve the KPIs

Enhance the 5S culture by conducting 5S internal audit twice per week

Develop high level process mapping for departments, swim lane and draw the full entire VSM to know the potential points for improvements in Production, supply chain and logistics areas

Implement OEE to improve machine capacity with developing the required support of PM

Implement Kitting system to suppliers and follow up the kits receptivity

Using different time study tools to improve the production processes and develop the SOP

Achievements:

Balance LBS assembly lines after changing it from batch production to be one-piece flow, which suits the required TAKT time and produce daily 52 LBS instead of average 36 LBS by 16 operators instead of 21 operators (Mega Project).

Improve the OEE in copper workshop by 12%

2013

Education:

Arab Academy for Science, Technology and Maritime Transport Master of Business Administration – MBA 2018 - 2020 Strategic Management – GPA: 3.88

Bachelor of Mechanical Engineering – Design & Production 2012 Last year grade: Very good (79%)

Graduation Project (Grade: Excellent): Implementation of lean Manufacturing principles in 3-Brothers Factory Using: Line Balancing, SMED & 5S Implementation from scratch with total savings of 7 HC Reduction and 90% M/Cs utilization improvement

Certified Lean Six Sigma Black Belt “CLSSBB” – CSSC

Regional XMB Trainer (Lean Simulation Coach) – General Motors

OpEx – General Motors

Internal XMB Trainer (Lean Simulation Coach) – General Motors Certificates:

2021

2020

2016

2015

Activities:

Member at student union of the Faculty of Engineering-Ain Shams University Participant at MECA – Lean Manufacturing & Supply chain Project at Exon Mobil 2012

2012

Skills:

Languages:

Arabic

English

Programs:

MS Office & outlook

SAP

Timerpro, STDS, APS

Solid work, Inventor

Personal & Soft Skills:

Change Agent

Leadership Problem Solving

Negotiation

Presentation Time Management

Communication

Decision Making

Other Contact Information

Date of Birth

Nationality

Marital Status

Military Status

Others

15th March 1989

Egyptian

Married

Exempted

Making

Valid Driving License and Passport

Valid B1/B2 US Visa

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