Mohamed Salah Abaza
________________________________________
Riyadh, KSA | +966.532289399 / +966.114235091 | mohammedabaza@gmail.com
Snapshot: Successful manufacturing & maintenance engineering professional with proven competencies in leveraging technical, analytical, leadership, managerial, people management and relations building skills & knowledge in delivering outstanding results seeking a leadership position with a reputable organization
Core Competencies include....
• Strategic Planning • Production Planning • Revenue/Business Growth
• Project Management • Project Budgeting/CAPEX • Quality Management System
• Manufacturing Operations • TPM, JIT, SIM, 5S, VSM • Change/Risk Management
• Manufacturing Plant Setup • Cost Optimization • KPI’s Corporate Reporting
• Lean Manufacturing • Inventory Management • Training & Development
• Process Improvement • Warehouse Management • Team Building & Leadership
Executive Summary
________________________________________
? Dynamic, resourceful Mechanical Engineer, MBA with 10+ years of rich hands on experience in manufacturing & maintenance engineering with reputable companies in the Middle East.
? Competent in deploying modern productivity enhancement methods & tools based on Lean Six Sigma to optimize processes to maximize productivity & profitability
? Extensive experience in adopting global best practices and contributing to organizational transformation projects delivering substantial benefits in performance improvement and cost savings.
? Experience of participating in projects to set up new production lines including feasibility assessment, cost estimation and line architecture.
? Adept in developing, implementing, reviewing and updating processes, systems, polices & procedures to enhance production, quality, cost effectiveness and safety of operations.
? Deft in building & sustaining productive relations with all key stakeholders and training, mentoring & motivating staff eliciting superior performances.
? Proactive, achievement driven professional with excellent communication, coordination, problem solving, decision making, planning and execution competencies.
Professional Experience
________________________________________
Schneider Electric, Saudi Arabia May 2008 to date
Career Progression:
• Manufacturing & Maintenance Engineering Manager (Jan 2013 to date)
• Acting Department Manager – Production Engineering (Sep 2012 – Jan 2013)
• Senior Methods Engineer – Production Engineering (Sep 2011 – Sep 2012)
• Methods Engineer – Production Engineering (May 2008 – Sep 2011)
Current Responsibilities:
• Monitor the manufacturing process assuring adherence to standard operating processes (means) & optimum utilization of resources to deliver customer expectations related to time, cost and quality and safety standards
• Plan and mobilize resources including machine loading & capacity and skilled workforce for smooth operation of the manufacturing process to achieve committed outcomes.
• Assure maintenance of specified quality levels by enforcing compliance with all approved processes & procedures.
• Coordinate the implementation & sustenance of TPM, improving operation & maintenance performance levels.
• Implement programs for optimizing performance and efficiency on the shop floor for continual improvements in productivity & profitability.
• Lead the implementation of the Plant Suggestion Scheme including generation of suggestions from employees, evaluation & implementation of viable suggestions.
• Ensure effective implementation and maintenance of 5S across all functional areas of the plant
• Coordinate and lead the process of training needs identification and training & development of employees to build competencies capable of meeting customer requirements.
• Participate in execution of the Performance Management System by providing inputs on performance data for dashboard cycles 1 & 2 in the information system
• Monitor and ensure compliance with rules & procedures related to the use of information systems – SAP & Kanban
Highlights:
• Implemented the Short Interval Management (SIM) tool across all plants as a part of the Schneider Global Change Management model with monthly Kaizen events which improved on time delivery, safety & quality
• Participated in integrating Saudi nationals in to the workforce through induction, orientation & training with sustainable productivity & quality to achieve the 2014-2015 Saudization target of 35%
• Participated in various projects – establishment of a new plant for load centre products, re-layout of RM6 plant representing turnover by 30% and a new line for producing Schneider transformers for the first time in KSA.
• Implemented measures to improve labour productivity by 12% contributing substantial improvement in margins
• Introduced one piece flow as part of Global Plants Transformation program for medium voltage products reducing production lead time by 35% and improving space utilization by 30%.
• Introduced in-line quality control tests during production reducing final quality control (FQC) activities & saving space, improving FAT date projection and reducing lead time by 2 weeks
• Organized annual Kaizen events to drive continual improvements in plants & lines with projects like wiring capacity management, fabrication machines improvements and ergonomics in material handling.
Previous Responsibilities:
• Supported the adoption of Lean manufacturing principles to optimize efficiency of production processes.
• Involved in introducing new products & processes, ensuring targeted return on investments for profitability.
• Led continual improvement programs to optimize plant performance on parameters of safety, quality, productivity, lead time, layout & surface
• Led process improvement teams in executing assigned projects deploying various process improvement methodologies like Kaizen to deliver predefined results and process improvements
• Trained team members on various aspects of Lean Manufacturing, Just in Time (JIT) and Kaizen for application in process improvements
• Enabled the business leadership in conducting meaningful project reviews by supplying support, tools and training.
• Coordinated the process of regular review & updating of all production documents and procedures
• Developed & maintained the database for factory equipment, BOMs and product routings
• Monitored and ensured compliance with health & safety regulations as per local legislation & company procedures by all employees as well as visitors to the company factory.
• Participated in the implementation of Schneider Production System (SPS) based on Lean Manufacturing principles at the site.
• Developed and updated work instructions, job descriptions & SAP records for product routing
• Contributed to make-or-buy decisions by evaluating plant capabilities & production costs through plant capacity analysis and workload analysis & supported subcontracting activities
• Improved tools performance by implementing concepts of predictive maintenance, metrology & calibration
• Implemented Lean Manufacturing methodologies like Kanban, 5S & SIM, conducted monthly audits and recommended action plans for improvements
• Conducted ergonomics studies for evaluating and improving manufacturing & stores activities.
Highlights:
• Led the development of new labour/line management tools aligned to Schneider Global Best Practices to improve customer service levels & productivity with sustainable quality standards along with an efficient CAPA management system for variations.
• Led implementation of the Warehouse Strategy project which reduced double-handling, waste generation and activities impacting quality leading to 15% saving in resources related to labour & equipment.
• Improved the process of monitoring costs of production processes, including forecasting of cost deviation improving accuracy of cost estimates for tendering and improved the divisional profitability
• Contributed to the successful launch of new products through cost control by optimizing material, equipment & labour costs.
• Deployed TPM which reduced machine & tool downtime by 30%, improving machine availability and capacity utilization
• Implemented Schneider Sales Inventory & Operations Planning (SIOP) system with weekly MPS for regular monitoring, positively impacting productivity & growth and improved global financial realization.
• Nominated as Industrial Performance Leader (IPL) in KSA for monitoring core processes and improving productivity in terms of labour hours and material usage.
• Standardized manufacturing activities and defined batch size for the product, gas insulated ring main unit RM 6, and reducing costs by 15%.
• Implemented global systems for provision & handling of MPH materials reducing manpower & transportation costs.
• Contributed to the increase in the annual production of RM6 main ring units from 7000 units to 21, 000 units improving market share in KSA.
• Implemented one piece flow method for medium voltage equipment improving process efficiency, reducing WIP and improving productivity by 12%
Fresh Electric Co. – Home Appliances, Egypt Sep 2005 – Apr 2008
Maintenance Manager – Machine Development
Responsibilities:
• Planned & executed Levels 3, 4 & 5 preventive & corrective maintenance schedules of plant & equipment to deliver targeted reliability & availability
• Established and managed the computer aided maintenance management system (CMMS) covering maintenance planning, maintenance & equipment history and spares planning.
• Trained personnel in CMMS and ensured adherence to CMMS procedures in all maintenance activities.
• Managed planning and inventory of spares & consumables ensuring optimum stock levels and consumption.
• Managed short term maintenance contracts for specific jobs to improve machine performance and reliability.
• Trained workers and setters on Levels 1, 2 & 3 maintenance of machines & equipment and monitored compliance with standard operating procedures (SOP)
• Implemented maintenance aspects of Short Interval Management (SIM) system to optimize factory performance.
• Monitored SIM activities related to Early Equipment Involvement and updated status of activities on the SIM display board in the department.
• Programmed PLCs through ladder diagram & flow chart method for process control of various machines.
• Participated in special assignments like turnkey projects for new product lines, production line improvements and debottlenecking of special purpose machines.
Highlights:
• Led the project team in setting up the first heating elements plant in the Middle East (Thermo Tech brand) including machine development and line architecture.
• Established production line for a new product – electric water heaters – including fabrication, installation & commissioning of machines for welding of inner/outer cylinder & cap insertion and welding of water piping
• Led the project for setting up a new plant for manufacturing water heaters in Ramadan City including set up
• Developed and all work instructions required for efficient and safe execution of all preventive maintenance and breakdown repair jobs.
• Participated in developing several special purpose machines with hydraulic & pneumatic systems.
• Implemented jobs for revamping of several old machines for improving process capacity and performance.
Education
________________________________________
• MBA, Operations Management, Specialization: Global Management, Grenoble Graduate School of Business, France, Mar 2014 GPA: 15/20 Project: Lean Manufacturing implementation in engineer-to-order (ETO) products
• Bachelor of Mechanical Engineering Concentration: Mechatronics, The Higher Technological Institute, Egypt, Aug 2005, 74%, Graduation Project on Robotics Technology – Won first prize in ROBOCON Egypt (Apr 2005) & an award at ROBOCON contest in Beijing China (Aug 2005)
Professional Development
________________________________________
• Materials & Supply Chain Management, Meirc Training & Consulting
• HSE – ISO 14001:2004 & OHSAS 18001:2007 – Certified Auditor, Bureau Veritas
• ISO 9001:2004 QMS Certified Auditor, Bureau Veritas
• Leadership Excellence Acceleration Program (LEAP), Global Integration
• Methodology of Time Management (MTM), Schneider Electric
• Lean Expert Training, Schneider Electric
• Lean SixSigma - Green Belt certification, Schneider Electric
• Finance for non-Finance Persons, Schneider Electric
• Lean Manufacturing Tools, Schneider Electric
Personal Details
________________________________________
• Date of Birth : 1st December 1983
• Nationality : Egyptian
• Languages : English & Arabic
• Address : 80 Turkey Ben Ahmed Alsudiri, Al-Nuzha, Riyadh, KSA
• Software : AutoCAD, Autodesk Inventor 3D CAD, Visual Basic, MS Office
• Professional Memberships : SAE International; ASME American Society of Mechanical Engineers (2004 to date)
• Visa Status : Transferable Saudi Iqama