Amr Khattab

Production Manager with experience across two distinct industrial sectors. Worked in hot-dip galvanizing operations within a steel processing company, focusing on furnace-based galvanizing processes and quality control. Additionally, gained solid experience in Prestressed Concrete Cylinder Pipe (PCCP) manufacturing at a separate concrete pipe manufacturing company, with hands-on involvement in steel fabrication operations including forming, welding, and assembly of steel components.

Demonstrated ability in production planning, material control, and process coordination to ensure efficient and high-quality manufacturing output.

Head Departments PCCP Production & Fabrication at Osman Group for Contracting and Specialized Industries (2012-04 – Present)

Leading PCCP production and fabrication departments with responsibility for production planning, quality control, and operational efficiency.

• Plan and manage production schedules, coordinating material requirements to ensure timely supply for uninterrupted production
• Allocate production tasks across shifts and optimize workflow to enhance operational efficiency
• Collaborate closely with Quality Control and Maintenance departments to improve OEE (Overall Equipment Effectiveness) and ensure compliance with technical standards
• Monitor raw material inspection plans in coordination with QC to verify conformity with ITP (Inspection and Test Plans) and specifications
• Track and analyze production performance, identifying opportunities to increase productivity and reduce scrap rates
• Conduct inventory reconciliation, comparing material usage against warehouse records and technical office calculations to ensure accuracy
• Develop and implement improvement plans to reduce defects and maintain waste percentages below agreed thresholds
• Review and approve supplier quality, monitor raw material test results, and ensure high reliability of supplied materials
• Organize and participate in safety meetings, update risk assessments, and implement measures to enhance workplace safety standards
• Evaluate worker and technician performance based on predefined KPIs and provide feedback for continuous improvement
• Generate daily reports on production volumes, material consumption, and operating conditions
• Oversee Non-Destructive Testing (NDT) of products, including magnetic weld tests and hydrostatic tests for steel and concrete pipes, preparing detailed follow-up reports
• Analyze defects, determine root causes, and implement corrective actions to prevent recurrence, ensuring products meet quality standards

Shift Production Engineer – Hot-Dip Galvanizing at Kandil Industries (KAMA) (2009-11 – 2012-03)

Supervised production shifts on hot-dip galvanizing furnace lines with team leadership and process optimization responsibilities.

• Supervised production shifts on hot-dip galvanizing furnace lines, leading a team of technicians to ensure smooth and efficient operations
• Monitored continuous production and lab/visual inspections, coordinating immediate corrective actions for any defects
• Oversaw annealing heat treatment process to ensure steel sheets were properly prepared for zinc coating
• Managed material usage, scrap, and zinc consumption, ensuring adherence to production targets and minimizing waste
• Recorded, analyzed, and reported production faults and downtime, implementing process adjustments to improve throughput and maintain quality standards
• Collaborated with quality, maintenance, and production teams to optimize operating conditions and support continuous improvement initiatives

Project / Production Engineer – Crushing Plant at Orascom Construction Industries (OCI) (2008-10 – 2009-10)

Supervised coarse aggregate production and equipment maintenance operations.

• Supervised coarse aggregate production, ensuring target size and quality
• Performed routine and preventive maintenance on jaw and impact crushers
• Adjusted crusher settings and resolved mechanical issues to maintain uptime
• Monitored production output, material flow, and equipment performance
• Maintained records of production, maintenance activities, and material usage

B.Sc. in Mechanical Engineering Production & Design – Helwan University (2003 – 2008)