Continuous Improvement Plant Manager

Wael Al-Zubeidi

Milwaukee, WI *****

414-***-**** *************@***.*** www.linkedin.com/in/wael-al-zubeidi

CONTINUOUS IMPROVEMENT LEADER

Driving significant results through dynamic foresight, strategy, and leadership of projects and teams

Results-driven with extensive complex manufacturing leadership experience. Broad-based expertise in building, executing, and leading effective strategies to achieve quality process improvements, attain significant cost savings, and enhance organizational efficiency and productivity by delivering quality results on time and budget—six Sigma Black Belt certificate. Examine processes and workflows to identify new opportunities for practical improvements. Deliver hands-on training, coaching, and mentoring to build top-performing teams that constantly achieve targeted business goals.

AREAS OF EXPERTISE

Business Analysis Process Improvement Efficiency & Productivity Improvements Lowering Costs

Lean Manufacturing Principles Six Sigma Training & Coaching Implementing Kaizen, VSM, PM Methodologies Lead Change Management & Transformations Build & Lead Strong Teams

PROFESSIONAL EXPERIENCE

ECHO LAKE FOODS

PLANT MANAGER FEBRUARY 2024-JANUARY 2025

As an accomplished and dedicated professional with a robust background in quality management and production within the food manufacturing industry, I bring a wealth of experience. I am a Plant Manager at Echo Lake Foods for the Burlington and Franksville Locations, a premier producer of high-quality egg and breakfast products. Echo Lake Foods is renowned for its commitment to food safety, operational excellence, and continuous improvement. With a focus on enhancing production efficiency, maintaining rigorous safety standards, and fostering a culture of innovation and teamwork, I have successfully driven initiatives that contribute to the company's success. My role involves overseeing day-to-day operations, implementing strategic improvements, and ensuring that we consistently meet and exceed our customers' expectations.

Managed and oversaw operations - Yorkville.

Mentoring program for management.

Managed and communicated with department heads regarding staff, safety, food quality, and inventory needs.

Managed personnel, oversaw labor, and determined staffing needs.

Managed plant budget and assumed responsibility for project management initiatives.

Managed GMP and HASAP programs and led the SQF audit process.

Led and managed the CI program.

Oversee maintenance and repair of plant equipment to minimize downtime and coordinate with maintenance teams to ensure all equipment functions properly and efficiently.

Managed plant budget, controlled costs, and worked to improve profitability.

Identify opportunities for cost savings and process improvements.

Implemented and monitored comprehensive safety management protocols, resulting in a 15% reduction in workplace incidents and ensuring compliance with all regulatory standards

GREBES BAKERY, WEST ALLIS, WI JUNE 2023- JANUARY 2024

Continuous Improvement Manager, Production Manager.

Hired to build a continuous improvement culture to reduce daily food waste from raw materials to finished products. Show a reduction in the waste of 500,000 dollars in the first six months to one million dollars in a year.

Created work standards and supported production by identifying and eliminating process limitations, wastes, and bottlenecks.

Evaluating and prioritizing potential improvements based on gains and required effort and identifying opportunities for process improvement, waste removal, and cost reduction.

Reduced waste rate from 4% to 1%, resulting in 500,000 dollars in savings in scraps. Analyzed production reports (OEE, downtime, waste, etc.) to determine causes of nonconformity with product specifications and operating or production problems.

Developed strong relationships with key members of the organization to understand better the overall business and upstream and downstream connections to prevent possible delays in production and shipment and impact on customer satisfaction.

Used solid problem-solving skills and supporting information to arrive at optimal decisions in an appropriate timeframe;

PURATOS CHOCOLATE USA, Kenosha, WI February 2023 – June 2023

The international group offers artisans a full range of innovative products and application expertise.

Production Manager

They provided plant leadership and manufacturing expertise to deliver results, directing daily production line operations for all shifts. They managed four direct reports, providing critical leadership and driving Continuous Improvement. They ensured active teams had solutions for safety, quality, and performance plans. They set tactical and strategic direction for each line and provided input for all site departments. They championed a belief in zero human and food safety incidents, driving safety improvements in Operations and throughout the plant.

Improved plant operating results while maximizing customer service by sharing resources with other departments, leveraging people, and improving production schedules that saved money and improved operating efficiency by 15%.

Streamlined operational processes by updating procedures to allow for increased efficiency.

Developed short- and long-term strategies to drive organizational effectiveness and productivity and improve key job-duty metrics.

Exemplified Servant and Engaging Leadership, establishing and maintaining positive employee relations company-wide, improving retention by 25%.

Educated, coached, and developed four Operations Supervisors to improve the team’s results.

Led gap closure and process standardization for operations, improving best practices and workflow consistency.

Participated as a Leadership Team member, providing counsel and support on crucial plant tactical and strategic initiatives, allowing employees to improve job expectations and career advancement opportunities.

Directed and led plant staff in developing, prioritizing, and implementing key initiatives supporting the Master Plan.

Coordinated daily activities to consistently ensure high performance and production.

Planned, organized, and directed daily operations to exceed customers’ expectations.

NESTLE BAKING & CONFECTIONERY, BURLINGTON, WI October 2020 – February 2023

Production Supervisor

Managed all production line operations to optimize productivity while delivering high-quality products and promoting employee safety. Revised staff instructions to support positions by analyzing work standards concerning safety protocol. Ensured organizational processes aligned with Standard Operational Procedures (SOPs) compliance. Evaluated finished manufacturing products in compliance with manufacturing practices, consistently exceeding consumer expectations. Reviewed vital information to drive long-term and short-term monthly and weekly targeted production goals, achieving performance improvements.

Wael Al-Zubeidi 414-***-**** *************@***.*** Page 2

Production Supervisor (continued)

Optimized workforce development and oversaw asset management by creating and launching an effective top-performing team.

Allocated resources and available products and delivered quality goods on time and within budget. Reduced manufacturing delay by 8 hours daily and delivery times to distribution center by 48 hours weekly.

Managed and drove TPM applications, including CL, CIL, Tagging, 5S, and lubrications across business units, reducing weekly machine downtime by 15 %.

Developed and steered a top-performing team to accomplish targeted manufacturing goals by implementing best practices and promoting continuous process improvements.

Served as Factory 5S Lead, partnering with the Operations Manager to create and deliver a continuous improvement workplace culture across production and warehouse operations.

Collaborated with Operations Manager and internal departments to design and institute lean processes.

HENKEL SURFACE TECHNOLOGY, Oak Creek, WI

February 2018 – October 2020

Worldwide, with leading innovations, brands, and technologies.

Production Supervisor

Led vision, strategy, and execution for all manufacturing, processing, and packaging aspects for adhesives designed for automotive industry applications, meeting production schedules and quality standards. Managed 40 hourly and salaried direct reports, fostering career development, establishing equipment maintenance best practices, process engineering, and quality control. Maintained complete compliance with all OSHA regulatory requirements governing site safety and corporate HSE standards.

SMITHFIELD FOODS, Cudahy, WI January 2012 – February 2018

Production Supervisor II

Led 90 production associates and support teams across eight manufacturing lines. Met and surpassed product and process quality targets while complying with complex state and federal regulatory requirements. She introduced best practices to govern quality, efficiency, and services at the division level. Contributed to monthly audits for plant safety, GMP, and SQF success by training employees and ensuring quality and production documents in compliance with the FDA and USDA agencies.

Orchestrated and executed Lean Six Sigma projects and Kaizen events facility-wide, improving profitability by 5%. Served as a trusted advisor and Subject Matter Expert (SME), guiding and directing employees on 5 Why and Six Sigma methodologies.

Established safety awareness programs, improving safety factors from 75% to 98% and achieving a flawless division safety record of zero accidents through 6S principles and ownership programs.

Introduced an Operator-Maintenance Partnership, establishing the operator as a first point of early warning and prevention, leading to a 30% reduction in downtime.

Debuted standardization and online process visualization to increase product yield from 65% to 88%.

Lowered product waste by examining and recommending changes to the slicing process.

Eliminated $1M in annual costs by contributing to acquiring new equipment and implementing Six Sigma processes that reduced staff from 10 to 2 employees.

EARLIER RELEVANT EXPERIENCE

OPEN SESAME FOODS, City, ST - Production Manager

KERRY FOODS & INGREDIENTS-AMERICA, City, ST - Production Supervisor

EDUCATION

Bachelor of Science, Industrial & Management Engineering, Montana State University, Bozeman, Montana

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