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.
