Manager Project

Location:

Plano, TX, 75025

Salary:

100000

Posted:

December 13, 2011

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Resume:

MICHAEL MAHFOUZ, MBA / Engineer

Production, Engineering, Maintenance Manager

**** **** ******* *****, *****, TX 75025

(h) 972-***-****, (c) 972-***-**** and ********@***.***

• Lean Production Engineer: Engineering leader with a relentless pursuit of better processes, equipment and systems. Talented equipment analyst combined with idea-man for modifications/improvements that optimizes speed, quality and reliability. Engineering experience includes environmental compliance, safety, facilities, mechanical, electrical, and IT.

• Energy and GHG Manager: Keen understanding of electrical and gas energy consumption with ideas for cost reduction. Recorded and tracked electric and gas energy expenses and created green energy management projects to reduce greenhouse gasses (GHGs) and related annual costs.

• Lean Manufacturing/Operations Manager: Lean production leader with talent for process analysis and improvement that results in millions of dollars cost savings in labor and material and improved quality. Recommended, planned, and executed new equipment purchases, equipment modifications, organizational effectiveness changes, and other continuous process improvements and culture changes in response to the business need for increased revenue and reduced costs.

• Project Manager: Attention-to-detail project manager and team leader of both small and large projects. Large projects include multimillion dollar equipment and system upgrades and plant startups. Created equipment and systems design and selection process to ensure equipment that works at optimum productivity. Establish professional relationships with equipment vendors and contractors.

• Continuous Process Improvement Manager: Engineer of both large and small process improvements, combined with standardization and QC that creates a culture of lean and productive manufacturing. Created and recommended a continuous stream of process improvements (kaizen) that increased sales and productivity and reduced operating expenses for numerous business departments. Impact of improvements at one plant was estimated to be nearly $100 million in annual cost savings and revenue increases.

• Organizational Effectiveness Manager: Reorganized/centralized several department functions and reduced related expenses. The changes improved organizational effectiveness and reduced annual costs over a million dollars.

• Plant Startup Manager: Startup manager and team leader for new plants. Two plants were nuclear power plants and one was major newspaper production plant. These projects were valued at millions of dollars.

• Plant Shutdown/Consolidation Manager: Planned and executed two plant closing projects valued at several million dollars. Moved some equipment as part of a consolidation to a central plant and disposed some obsolete equipment. Organized central plant space so that consolidated equipment fit for an organized work flow. Key team member to sell properties.

PROFESSIONAL EXPERIENCE

SR. PRODUCTION DIRECTOR / ENGINEER. The Dallas Morning News. 2005–2011

Managed a team of 75 to 100 plant operations and maintenance employees including mechanical, electrical, systems/data/IT, building maintenance, facilities, security, environmental compliance and safety, and admin. Data driven decision making. Annual operating budget approximately $10 million.

• Continuous Process Analysis and Improvement (CPI). Submitted a continuous stream of lean process improvement recommendations from manufacturing operations and maintenance to purchasing and accounting.

• Plant Startup Manager. Installed new manufacturing equipment and systems and made modifications with manufacturer, contractors and in-house staff. Optimized productivity and quality.

• Commercial Product Startup Manager. Managed the startup of several new commercial customers including: USA Today, Wall Street Journal and Investors Business Daily. Designed and created unique production lines designs. Increased revenue ~$80 million.

• Equipment Selection and Capital Project Manager. Equipment design and performance and data analysis used to select best equipment and systems for optimum performance.

• Plant Closings and Consolidations. Planned and executed closing of a commercial print manufacturing plant, Sunday collating and packaging plant, truck tower, and distribution centers that saved ~$3 million annually.

SR. DIRECTOR OF ENGINEERING AND MAINTENANCE. New York Daily News. 1998-2005

Managed team of 150 employees in systems/data/IT, electrical, and mechanical engineering; facilities; environmental compliance and safety. Major manufacturing plant modifications that improved the business from an annual net loss to ~$20 million annual profit.

• Engineering and Legal. Consultant to management, engineering, and legal for first two years. Won major legal case involving substandard equipment and systems for ~$10 million. Also won a major court victory involving labor relations that resulted in a significant cost savings.

• Packaging Plant Modifications. Purchased, installed, and major player in design of new equipment and systems that worked doubled productivity and halved costs. Annual cost savings and revenue impact was ~$5 million.

• Press Plant Modifications. Managed the start of color ink printing and modified all nine printing presses to improve overall performance approximately 40%. Annual ad revenue and cost savings impact was ~$10 million.

MANAGEMENT and ENGINEERING CONSULTANT. DeNardo Consulting Group. 1997-2000

Improved processes and organizational effectiveness in several cities and business units including: production, engineering, accounting, advertising, human resources, distribution, pressroom, packaging and print shop. Annual revenue increases and cost savings in labor and material far exceed $10 million.

PRODUCTION ANALYST / ENGINEER. The Dallas Morning News. 1988-97

Dual role as financial analyst and operations engineer for Packaging and Production departments. Managed Packaging operations and Production expenses and developed capital improvement projects.

ADDITIONAL EXPERIENCE

CUSTOMER SERVICE ENGINEER. Arkansas Power and Light Company. Large industrial/commercial customer account executive and energy management consultant. Identified and presented numerous Company and customer cost savings proposals.

UNIVERSITY ENGINEERING INSTRUCTOR Arkansas Tech University. Full responsibility to teach classes create lesson plans, lecture class; assign and grade homework; create, administer, and grade exams, etc. Designed and built ethanol still and wrote lab manual.

NAVY NUCLEAR POWER PLANT SENIOR SUPERVISOR. Lead mechanical department supervisor of operations, engineering, maintenance, and training. Plant start-up manager, and lead instructor. National Reactor Testing Station, A1W Training Facility and USS DD Eisenhower aircraft carrier (CVN-69 Plank Owner). Identified and managed numerous productivity improvements and cost savings that resulted in citations from Secretary of Navy and Westinghouse (see below).

PROFESSIONAL RECOGNITION

NAVY ACHIEVEMENT MEDAL from Secretary of the Navy for cost sav¬ings, professional achievement, techni-cal compe¬tence, and exemplary leader¬ship.

COMMENDATION FOR ACHIEVEMENT from Westinghouse Corporation Plant Manager for exceptional performance, leadership, and nuclear plant knowledge.

MAGNA CUM LAUDE and ALPHA CHI at undergraduate universi¬ty.

EDUCATION AND TRAINING

MASTER OF BUSINESS ADMINISTRATION (MBA) in Organization and Strategy (theme is leadership and organizational effectiveness) and International Business, University of Texas at Dallas

BS MECHANICAL ENGINEERING, magna cum laude, Alpha Chi (national honor scholarship society), Arkansas Tech University, Russellville, AR

NUCLEAR POWER PLANT OPERATOR AND INSTRUCTOR SCHOOL, Nuclear Power Plant Quality Control School, Naval Reactors Facilities, National Reactor Testing Station, Idaho Falls, ID. Nuclear Power (nuclear and mechanical engineering) School, Mare Island, CA.

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