Ahmed Essam

Ahmed Essam Email and Phone Number

Manufacturing Operations Excellence , , Production Management Professional, Lean Manufacturing , Assembly, Plastic injection , Plastic exrtusion , Manufacturing Manager @ Nova Plastik San. Tic. A.Ş.
bayrampasa, istanbul, turkey
Ahmed Essam's Location
Cairo, Cairo, Egypt, Egypt
About Ahmed Essam

Creative, System Thinker, Energetic, with 17 years management & engineering experience. I worked in great re-engineering projects as well as cost saving and optimization solutionsMy experience gained from Working in a great companies from different fields (Sheet Metal ,Plastic, Home Appliances Assembly ,Crystal , Cables ) in and out Egypt . My Objective is Implementing modern philosophies ,tools ( Lean Manufacturing , Six sigma )in industry to improve reach world class level .My job responsibility is Leading Resources to achieve the best performance from them .

Ahmed Essam's Current Company Details
Nova Plastik San. Tic. A.Ş.

Nova Plastik San. Tic. A.Ş.

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Manufacturing Operations Excellence , , Production Management Professional, Lean Manufacturing , Assembly, Plastic injection , Plastic exrtusion , Manufacturing Manager
bayrampasa, istanbul, turkey
Website:
novaplastik.com
Employees:
26
Ahmed Essam Work Experience Details
  • Nova Plastik San. Tic. A.Ş.
    Production Operations Manager
    Nova Plastik San. Tic. A.Ş. Jun 2024 - Present
    10Th Of Ramadan, Sharkia, Egypt
    -Manage the technical team and blue-collar team, lead them to streamline injection molding and assembly operations.-Assure the efficient and high-quality production in the facility. - Performance monitoring, manpower and capacity planning, maintenance planning, and quality control and process improvements. The top-level operations supervisor and will be in charge of managing the Injection Molding, Assembly, Quality Control and Assurance, Maintenance and Warehouse departments.
  • El Alameya For Car Plastics  Auto Plast
    Production Operatorions Manager
    El Alameya For Car Plastics Auto Plast Jan 2023 - May 2024
    10Th Of Ramadan, Sharkia, Egypt
    •Supervise operations team in the shop floor contains PP Hollow Sheets Extrusion, Plastic ultra sonic welding, cutting, finishing machines, Injection molding machines.•In charge of Plant Maintenance, Production, Quality sectors.• Develop and lead manufacturing engineering activities to improve the use of machinery (OEE) and improve of manufacturing methods focusing on productivity, labor efficiency and machinery utilization, and First Time Yield (FTY).• Organize Improvement of productivity and manufacturing efficiency by analyzing use of work force, space requirements and layout across operations in the plant.• Drive new products feasibility studies, preliminary cost estimation for tools and equipment modification and related timing, Prepare, manage and follow capital expenses (CAPEX) plan for Equipment.• Review of technical specifications for equipment, including safety.
  • Schwabe
    Production Manager
    Schwabe Nov 2020 - Feb 2023
    6Th Of October, Al Jizah, Egypt
    • Supervise a multifunctional Shop floor mainly focus on electrical accessories and led bulbs assembly lines.• The Main Processes in shop floor are Products assembly lines, Packing lines.• Organizing the daily production activities and solving any technical problems.• Redesign the Production line Processes to satisfy the quality requirements and achieve the production goals, reducing REWORK and assembly defects percentage.• Supervising the production staff to Create the work instructions, the products SOPS.• Identifying the necessary resources from the raw material and manpower necessary to execute the production plan.• Analyzing the production line processes to minimize the waste and balancing the standard time of the processes to maximize productivity by using lean manufacturing principles. • Creating and coordinating the implementation of manufacturing processes • Presenting timely reports to Plant Manager in relation to the production plan execution and corrective actions taken.• Managing over 400 Labors.
  • Zamzam For Engineering Industries
    Production Manager
    Zamzam For Engineering Industries Oct 2019 - Oct 2020
    6Th Of October
    · Leading a package of projects to construct a platform for modern production involve:· Training a team of 4 production engineers and 15 technicians to launch lean philosophy and its tools(kaizen, 5s, Poka Yoke, QCO, OEE, etc.) in the factory.· Calculating Machines an Operators capacities due to processes and Re-designing the (processes flow,arrangement – machines position) 15 production group for Sheet metal and Aluminum products tocreate an ideal capacity plan.· Study, analysis 125 (Alum, Galvanized steel) products to create products matrix contain ideal (cycletime, consumption, no of operators, amount of utilities).· Create and renew Standard operation procedures for 125 products.· Create KPIS For Production departments as a method to evaluate the factory and the employees.· Resolving manufacturing discrepancies and determining true root cause through to solutionimplementation.· Design a Suitable Indicators sheets to follow up the Daily activities in every production groups.· Design a Suitable Indicators sheets to follow up the capacity of job orders in every production groups.· Good Knowledge about Sheet metal, Aluminum sections Fabrication Methods, Machines.
  • Al Faisal Plastic Factory
    Production Manager
    Al Faisal Plastic Factory May 2018 - Aug 2019
    Jeddah Governorate, Saudi Arabia
    • Organizing, re-arranging all Blow molding, Injection of Plastic production process with Key Performance Indicators.• Plan a production schedule for the Sales orders.• Implement and control the production schedule.• Review and adjust the schedule where needed.• Determine the human, material resources required.• Manage human and material resources to meet production targets.• Make decisions about equipment use, maintenance, modification and procurement.• Work out and implement standard operating procedures for production operations.• Ensure that standard operating procedures are adhered to.• Ensure implementation and adherence to health and safety procedures.• Monitor quality standards of products.• Implement and enforce quality control and tracking programs to meet quality objectives• Analyze production and quality control to detect and correct problems• Determine and implement improvements to the production process• Prepare and maintain production reports.• Monitor and review the performance of staff and organize necessary interventions for improvement.• Estimate production costs.• Set production budgets.• Manage production budgets.• Implement cost control programs.• Ensure efficient collaboration and co-ordination between relevant departments including procurement, distribution and management.ACHIEVEMENTS: (9% Productivity increase)
  • Asfour Crystal
    Fasion Elements Production Section Head
    Asfour Crystal May 2017 - Apr 2018
    Egypt
    • Organize and manage 23 units for produce fashion Elements.• Plan and coordinate production engineering processes on daily basis to produce high quality products.• Develop process improvements to effectively utilize equipment and materials to maximize production.• Develop operational strategies to achieve production and financial objectives.• Identify unsafe operations and practices and report the same to Manager immediately.• Drive the implementation of manufacturing techniques (5S, value stream mapping; pull system sand Kaizen etc.) to improve workflow; reduce cycle time, and costs)• Establish safety procedures and environmental regulations for employees.• Provide engineering support for production and maintenance activities to ensure maximum production.• Made the experiments to run the factory products on the new machines with the best performance.• Perform engineering analysis to reduce downtime and outages.• Evaluate current production activities and make recommendations for improvements.• Implement cost reduction initiatives while maintaining high quality standards.• Develop operating instructions and equipment specifications for production activities.• Provides training and guidance to team members to accomplish production goals.• Stay current with product specifications, engineering technology and production processes.• Investigate problems, analyze root causes and derive resolutions.• Aid in budget preparation and monitor expenses and profitability.Managing over 340 labors.ACHIEVEMENTS (20% Cost Saving from Direct labor cost ).
  • Asfour Crystal
    Chinees Semi-Automatic Grinding Lines Unit Section Head
    Asfour Crystal Jun 2015 - Apr 2017
    Egypt
    • Designed the processes of production, machines layout, motion study for operators.• Made the experiments to run the factory products on the new machines with the best performance.• Designed Job responsibly of all Labor levels and account them.• Designed The documentation system for work procedures.• Drive the implementation of manufacturing techniques (5S, value stream mapping; pull systems, SMED, TPM, and Kaizen etc.) to improve workflow; reduce cycle time, and costs)• Calculate and monitor OEE of machines.• Designed Training Program and the material for the operators to run the new machines.• Manage the unit with the selected Key performance indicators. • Establish safety procedures and environmental regulations for employees.• Plan and coordinate production engineering processes on daily basis to produce high quality products.• Develop best practices to improve production capacity, quality and reliability.• Investigate problems, analyze root causes and derive resolutions.• Aid in budget preparation and monitor expenses and profitability.• Managing over 70 labors. ACHIEVEMENTS : (15% Cost Saving Form Productivity increase ).
  • Asfour Crystal
    Grinding And Polishing Unit Production Engineer
    Asfour Crystal May 2013 - Apr 2015
    Egypt
    • Plan and coordinate production engineering processes on daily basis to produce high quality products.• Develop process improvements to effectively utilize equipment and materials to maximize production.• Develop operational strategies to achieve production and financial objectives.• Identify unsafe operations and practices and report the same to Manager.• Drive the implementation of manufacturing techniques (lean, 5S, value stream mapping; pull systems, SMED, TPM, and Kaizen etc.) to improve workflow.• Establish safety procedures and environmental regulations for employees.• Perform engineering analysis to reduce downtime and outages.• Evaluate current production activities and make recommendations for improvements.• analyze root causes and derive resolutions.• Aid in budget preparation and monitor expenses and profitability.• Managing over 170 labors.
  • Asfour Crystal
    Chatons Preparing And Packing Engineer
    Asfour Crystal Jun 2011 - Apr 2013
    Egypt
    • Evaluate and analyze current process metrics and performance to identify areas requiring improvements.• Optimizes operational productivity (eliminate waste, refine staffing models, off-shoring, etc.) and management system effectiveness (value stream alignment, continuous improvement, etc.).• Facilitate the deployment of new and changed processes to provide improved results.• Develop standard procedures and policies .• Train and guide resources as needed.• Work with various teams to reduce process and business variations.• Assist Managers in management for capital projects.• Minimizing waste by analyzing the workflow processes for reducing cost and cycle times.• Prepare project presentations for management when needed.• Aid in budget preparation and monitor expenses and profitability.• Managing over 100 labors. ACHIEVEMENTS (35% Cost Saving from Productivity increase and Direct Labor Cost ).
  • Elsewedy Electric
    Mechanical Workshop Engineer
    Elsewedy Electric Aug 2008 - Jun 2011
    Egypt
    • Drive Spare parts and Utilities work shop (welding, Turning, Milling).• Manages day-to-day operations including equipment preparation and maintenance, safety standards.• Creates instructions for machinists and operators.• Analyzes job order and performs necessary calculations.• Chooses Material and Calculate the amount that will be needed.• Coordinates with curriculum management to determine equipment/consumables purchase priorities based on budget allowances, condition of existing equipment.• Manage over 50 operators.
  • National For Real Estate Marketing & Consultancy
    Appraisal Engineer
    National For Real Estate Marketing & Consultancy "Assets" Jul 2007 - Jul 2008
    Cairo, Egypt
    • Make the visits to the establishments for which assets are to be evaluated.• Prepare reports on the number and status of existing mechanical and electrical assets.

Ahmed Essam Skills

Engineering Autocad Team Leadership Manufacturing Microsoft Office Lean Manufacturing Team Management Analysis Continuous Improvement Lean Thinking Solidworks Toyota Production System Machining Communication Skills Lean Tools Lean Management Internet Of Things Glass Crystal Ball Crystal Fabrication Glass Technology Kaizen Kanban Kaizen Leadership Poka Yoke 5s Pdca Smed Hoshin Kanri Value Stream Mapping Time Management Cost Reduction Cost Control Visual Factory Management Work Standardization Andon Ergonomics Cellular Manufacturing A3 Thinking Tpm Leadership Leadership Development Communication Product Development Project Engineering Project Planning Factory Total Productive Maintenance Employee Training

Ahmed Essam Education Details

Frequently Asked Questions about Ahmed Essam

What company does Ahmed Essam work for?

Ahmed Essam works for Nova Plastik San. Tic. A.ş.

What is Ahmed Essam's role at the current company?

Ahmed Essam's current role is Manufacturing Operations Excellence , , Production Management Professional, Lean Manufacturing , Assembly, Plastic injection , Plastic exrtusion , Manufacturing Manager.

What schools did Ahmed Essam attend?

Ahmed Essam attended Benha University.

What are some of Ahmed Essam's interests?

Ahmed Essam has interest in Social Services, Children, Civil Rights And Social Action, Politics, Education, Environment, Science And Technology, Animal Welfare, Arts And Culture.

What skills is Ahmed Essam known for?

Ahmed Essam has skills like Engineering, Autocad, Team Leadership, Manufacturing, Microsoft Office, Lean Manufacturing, Team Management, Analysis, Continuous Improvement, Lean Thinking, Solidworks, Toyota Production System.

Who are Ahmed Essam's colleagues?

Ahmed Essam's colleagues are Pavel Ogienko, Uğur Dal, Orhan Volkan, Seda Bektaş, Zafer Tanrıtanır, Özge Kuşoğlu, Ramazan Köse.

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