Mostafa Helal

Production & Maintenance Manager with 15+ years in chemical powder manufacturing — responsible for the full production cycle from MRP-driven scheduling and capacity planning to preventive maintenance, OEE optimization, and ISO 9001 / GMP regulatory compliance across 10 departments. Achieved $50K+ annual cost savings, reduced unplanned downtime by 30%, and increased plant productivity by 40% through Lean Six Sigma re-engineering, CMMS implementation, and RCA/FMEA-based maintenance. Proven ability to lead cross-functional teams, manage Capex budgets, and coordinate with supply chain — delivering measurable results within the first quarter of engagement.

Production & Maintenance Manager at International Development and Investment Company (IDIC) (2010-10 – Present)

Full P&L accountability for production output, maintenance reliability, quality assurance, and regulatory compliance — managing 10 departments and owning the plant's complete production and maintenance cycle.

• MRP-driven production scheduling: Translated monthly and annual sales forecasts into master production plans, coordinated with procurement and supply chain teams to secure raw material availability, and adjusted capacity dynamically to meet delivery targets.
• Capacity optimisation: Overhauled production scheduling through comprehensive workload assessments — increased overall plant productivity by ~40% while sustaining ISO-aligned quality standards.
• Production KPIs & reporting: Developed balanced scorecards and real-time KPI dashboards tracking output, yield, OEE, and quality metrics across all production lines — enabling data-driven daily decision-making.
• QMS & SOP authorship: Built and implemented the plant's Quality Management System (QMS); authored SOPs for all critical production processes, establishing documentation baseline for ISO 9001 certification alignment.
• GMP & regulatory compliance: Maintained full GMP compliance across production and packaging operations; oversaw 52+ hours of internal audit execution with zero major non-conformances across consecutive audit cycles.
• OEE improvement: Improved Overall Equipment Effectiveness by reducing unplanned downtime by ~30% — tracked via MTBF and MTTR metrics — through transition from reactive to preventive and predictive maintenance.
• CMMS implementation: Deployed CMMS platform centralising asset registry, work orders, PM scheduling, and spare parts inventory management — replacing manual tracking and enabling maintenance performance analytics.
• RCA & FMEA: Applied Root Cause Analysis and FMEA methodologies to resolve chronic equipment failures in fluid bed systems and boiler operations, delivering sustained reliability improvements.
• Incident response: Established rapid-response maintenance protocols with clear escalation paths — reduced incident resolution time by ~40% and eliminated recurring production stoppages.
• Preventive maintenance: Designed and executed the plant's first structured PM programme, reducing resource wastage by ~20% and building a culture of planned maintenance over breakdown firefighting.
• $50,000+ annual savings: Identified and resolved excessive natural gas consumption per ton of product through process analysis and equipment tuning — delivering verified cost reduction without capital investment.
• Lean re-engineering: Spearheaded company-wide process re-engineering across 10 departments using Lean / Six Sigma principles (5S, Kaizen, DMAIC) — digitised workflows, reducing inter-departmental paperwork processing time by ~75%.
• CapEx & budget management: Managed annual maintenance and CapEx budget — planned and delivered all projects on time and within budget, aligned with long-term capacity growth strategy.
• Manpower planning: Led workforce planning and team development across 10 departments — structured roles, defined accountability frameworks, and built a performance-driven operational culture.
• HAZOP & safety: Implemented hazard identification (HAZOP) and risk mitigation frameworks across all operations; ensured full OSHA compliance and maintained zero LTI record through systematic safety protocols.

Production Engineer at ABCO — Detergent & Cosmetics Manufacturer (2010-03 – 2010-10)

Managed operation, scheduling, and troubleshooting of boilers, softeners, and water treatment stations; ensured production targets and equipment uptime were met.

Chemical Engineer (National Service) at Egyptian Armed Forces (2008 – 2009)

Designed and operated wastewater treatment systems; conducted QC testing for water supplies in compliance with health and safety standards.

Bachelor of Science in Chemical Engineering – Alexandria University, Faculty of Engineering (2008)