Abdullah Shawky
Riyadh
Summary
17 Years of experience in - Plastic industrial (Blown Film, Masterbatch, PVC Compound, PVC pipe , PE pipe) -Paper Cup manufacturing, with a very strong knowledge in - Smooth Operations -Production management -Supply Chain Management -Manufacturing Process Development -Product Development -ERP Manufacturing -Q.C Management -Performance Analysis -Cost Analysis, Production Increase, Troubleshooting Proactive Production Manager successful at anticipating needs and making adjustments to schedules, materials and workflow. . Multi-talented Production Manager experienced in diverse industrial environments. Profit-motivated collaborator with ingenuity in troubleshooting complex productivity obstacles. Creative leader with motivational supervisory methods.
Overview
18
18
years of professional experience
1
1
Certification
Work History
Production Manager
NEOP Plastic
01.2023 - Current
- Oversee the Manufacturing implementation and training on ERP to assure the accuracy and consistency of registered data
- Prepare BOM and monitor the variances
- Oversee Creating Product Manual
- Enhance All Production Sections productivity
- Measure and report production KPI's (OEE, BOM, Waste Control, Fault Analysis) for the purpose of performance monitoring, cost variances monitoring
- Liaise with Sales and FG Warehouses staff to measure demand and prepare annual and monthly MPS (Master Production Schedule)
- Review raw material stock on hand and prepare MRP (Material Resources Plan)
- Organize workflow to meet specifications and deadlines
- Establishing a balance between increased productivity and reduced costs of manufacturing operations
- Setting productivity goals for each manufacturing team
- Monitor the production processes and adjust schedules as needed
- Ensure customer orders are completed on time and to budget and that quality standards and targets are met
- Higher availability rate of Finished Goods
- Increase OEE from 67% to 85%
- Increase Production volume 20%
- Decrease customer complaints
- Creating products using 100% recycled materials
- Develop & Repairing 9-ton waste ink
- ERP Manufacturing implementation
- Increase Productivity
- Smooth Operation
- Enhance Working Environments
- Decreasing Coast
- Planning & Analysis
- Resolved issues quickly to maintain productivity goals.
- Managed multiple projects concurrently, ensuring timely completion and meeting budget constraints.
- Increased overall productivity by identifying bottlenecks in the production process and proposing effective solutions.
- Oversaw quality control efforts, maintaining strict adherence to industry standards and regulatory requirements while achieving high levels of customer satisfaction.
Acting Plant Manager - Paper Cups plant
Rema Factory for Plastic Products
01.2021 - 01.2023
- Oversee the implementation and training on SAP ERP to assure the accuracy and consistency of registered data
- Prepare BOM and monitor the variances
- Implement MTM (Method Time Measurement) and Time Motion Study to assure continual enhancement in factory operations
- Contact Paper suppliers to request quotations, discuss material specifications, negotiate prices, and prepare comparison matrix to discuss with top management to assign the vendor
- Measure and report production KPI's (OEE, BOM, Waste %, Machines RF, Fault Analysis) for the purpose of performance monitoring, budget preparation, cost variances monitoring
- Liaise with Sales and FG Warehouses staff to measure demand and prepare annual and monthly MPS (Master Production Schedule)
- Review raw material stock on hand and prepare MRP (Material Resources Plan)
- Liaise with warehouses to assure raw material availability and carry out the required actions
- Study updated technologies in the industry to assure attaining the new developments and contact machine suppliers to request new production lines when need raised and discuss the financial and technical offers
- Provide the required training and coaching for subordinates, and report the appraisal
- Oversee the maintenance operations, and liaise the operation and maintenance team to assure high machine reliability
- Higher availability rate of Finished Goods
- Null Shortage of raw material
- Increase OEE from 32% to 83%
- Increase Production volume 6 times
- Decrease customer complaints
In Charge of Supply Chain in Plastic & Paper Cups Plants
Rema Factory for Plastic Products
06.2020 - 01.2021
- Machines (Logistics)
- Imported raw materials
- Paper
- Determine Demand Planning, and managing Supply Planning, Purchasing and Logistics Services
- Define inventory objectives, inventory level and risk mitigation objectives, and manage a resilience strategy for inventory improvement
- Monitoring the performance of the supply chains of external suppliers while dealing with internal logistics
- Negotiate contracts, policies and deadlines with suppliers
- Department of dealing with government systems (industrial, saber, Saudi customs, customs brokers and customs exemptions)
- Dealing with government systems (SINAIE site, saber, Saudi customs, customs brokers and customs exemptions)
- Monitoring the performance of the supply chains of external suppliers while dealing with internal logistics
- Reducing inventory level, which leads to maximizing the investment return
- The flow of raw materials is not turbulent
- Smooth supply without fines and without facing systemic problems
- Improving payment terms from cash to credit 150-day
- Defined or refined KPIs signaling success for partners across quality, performance and cost-efficiency dimensions and drove improvements in target metrics.
- Developed and maintained strong relationships with industry experts and professional organizations to stay current on best practices and emerging trends, driving ongoing improvements.
- Successfully managed complex projects involving multiple stakeholders across different regions around the world.
- Increased on-time delivery rates through effective communication and coordination among team members.
Research and Development Engineer in Plastic Plant
Rema Factory for Plastic Products
05.2018 - 06.2020
- Fragrance Masterbatch Project: Stage1: Bench trials to produce masterbatch inhouse to decrease the cost through eliminating lost volatile proportion of fragrance during masterbatch manufacturing and film production processes
- Stage2: Build pilot plant for making trial quantities and measure process variables to design production line
- Stage3: Design production line and manage the request, delivery, of equipment, and material
- Stage4: Installation and startup of production line
- Stage5: Manage the production Process and cost optimization
- Stage6: Continual development of process variables and KPI's
- Enhance Film section productivity: Implement technical assessment to indicate the clear gaps and corresponding corrective actions
- Specify inspection points and build the process report
- Conduct the required training for staff and assure the awareness
- Implement measurement and continual evaluation
- Carry out the corrective and preventive actions
- Establishing the Laboratory Department: Reviewing products according to Saudi standard specifications
- Identifying the necessary devices and tools for measurement
- Propose the corrective and preventive actions
- Requesting quotations for devices and tools
- Selecting the best offers and supervising their supply
- Training quality technicians on how to use the devices
- Identifying inspection points and building a report on the process
- Conducting the required training for employees and ensuring awareness
- Implementing continuous measurement and evaluation
- Implementing corrective and preventive measures
- Enhance Paper Cups Quality: Study of production process and the reoccurring product defects
- Implement Root Cause Analysis for each defect
- Propose the corrective and preventive actions
- Implement the corrective actions and evaluate the cause-effect
- All stages were accomplished for the first line, and second line were added due to the increase in demand
- New fragrances and products were added to products portfolio
- Product is the first choice for customer in Saudi market
- All required fixes were accomplished
- Training was accomplished with notable increase in level of awareness
- Enhancement of film quality which affected the upstream processes (printing & converting) positively
- Production volume increased 25% without adding new lines, or further labor
- Raw material, In-Process, and FG inspection plan were documented and implemented
- The laboratory department was established, and laboratory tests were included in quality testing
- Compliance with Saudi standards was ensured
- Film quality was improved and quality control was increased
- The ability to identify Issue after measurements was achieved
- Raw material, In-Process, and FG inspection plan were documented and implemented
- Quality lab equipment and devices were requested and supplied
- Employee's training was accomplished
- Raw material specifications were changed without negative effect on cost
- New technicians were hired to fill the gap in technical experience
- New paper suppliers and vendors were added to reach the required quality with competitive prices
- Decrease waste ratio 30%
- Increase profit ratio 3 times
Central Lab and R&D Manager
Miser Elhegaze Group
01.2012 - 05.2018
- Managing with depth investigations into product recall to identify root causes and develop action plans to avoid future errors
- Develop effective quality control processes, and design based on current operational flaws and government regulations
- Production is closely monitored, ensuring that product development remains accurate and within the company's high-quality standards
- Managed inspections and error detection
- Managed processes for product rejection and approval, and decision making based on quality and safety
- Perform comprehensive quality assessments to determine if products meet the company's high quality standards
Senior Quality Control Engineer
Miser Elhegaze Group
05.2009 - 01.2012
- Preparing Up-to-date documentation of rejected components and finished products
- Check for non-conformities product
- Review supplier materials and compare with TDS
- Inspect production, processing and transportation processes for compliance with government standards
- Produce results reports to assist senior leadership in improving operations
- Inspect and test products and materials to ensure their compliance with specifications and standards
Production Engineer
Miser Elhegaze For PVC Compound
01.2007 - 05.2009
- Develop and Improve Manufacturing and Production Processes To Improve Quality And Reduce Waste And Costs
- Implantation of Delivery Schedules
- Develop Production Plans Schedules
- Partnership with Management In Establishing And Implementing Production Methods, Techniques And Equipment
- Evaluate Current Work To Understand Strategies And Help Improve Employment Use
Education
Bachelor of Science - chemistry
Cairo Unvisity
Egypt01.2007
Skills
- Inventory management
- Product development
- Competitor analysis
- Time management
- Increasing production
- ERP implementation
- Operation Management
- Performance Measurement
Certification
- Six sigma certified
- Accountant for non-accountancy's certified
Timeline
Production Manager
NEOP Plastic
01.2023 - Current
Acting Plant Manager - Paper Cups plant
Rema Factory for Plastic Products
01.2021 - 01.2023
In Charge of Supply Chain in Plastic & Paper Cups Plants
Rema Factory for Plastic Products
06.2020 - 01.2021
Research and Development Engineer in Plastic Plant
Rema Factory for Plastic Products
05.2018 - 06.2020
Central Lab and R&D Manager
Miser Elhegaze Group
01.2012 - 05.2018
Senior Quality Control Engineer
Miser Elhegaze Group
05.2009 - 01.2012
Production Engineer
Miser Elhegaze For PVC Compound
01.2007 - 05.2009
Bachelor of Science - chemistry
Cairo Unvisity
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