Mohamed Mahdy Email & Phone Number

El Mansoura, Ad Daqahliyah, Egypt

• Designed, optimized manufacturing processes, improved efficiency by 20%, and reduced production costs by 15%.• Conducted feasibility studies and process simulations to evaluate new manufacturing technologies.• Developed and implemented standard operating procedures (SOPs) to ensure consistent and efficient operation of manufacturing processes.• Collaborated with cross-functional teams to troubleshoot production issues, implement corrective actions, and ensure compliance with quality standards and regulatory requirements.• Led continuous improvement initiatives, such as lean six sigma projects, to identify and eliminate waste.• Provided technical support and training to production personnel to empower them to troubleshoot process issues and perform routine maintenance tasks effectively.• Participated in new product development projects, providing input on design for manufacturability (DFM) considerations and process scalability.• Conducted process validation studies and authored validation protocols and reports in compliance with regulatory requirements (e.g., IATF 16949, ISO, BIQS).• Developed a coding structure for categorizing all factory items, comprising over 20,000 individual items.• Responsible for materials coding.• Responsible for product data, bill of material, bill of operation, and resource data on SAP.• Owner of PPAP and APQP processes, responsible for developing and maintaining product process flowcharts, conducting PFMEA and CP activities, and facilitating communication with OEM companies regarding specification, cost, and quality assurance.• Assess process capacity against production needs, swiftly addressing any shortcomings to ensure seamless fulfillment of production requirements and maintain operational efficiency.• Identify any bottlenecks or constraints in the production process that may limit capacity, such as equipment downtime, labor or material shortages.

El Mansoura, Ad Daqahliyah, Egypt

• Successfully led a process engineering team through periods of growth, hiring, and training new team members to expand capabilities and meet increasing project demands.• Implemented professional development initiatives such as mentorship programs, training workshops, or certifications to enhance the skills and expertise of team members.• Led the successful execution of complex process engineering projects from concept to completion, meeting or exceeding project objectives, timelines, and budgetary constraints.• Implemented project management best practices such as risk management, resource allocation, and stakeholder communication to ensure project success.• Spearheaded initiatives to optimize manufacturing processes, resulting in improved efficiency, reduced waste, and enhanced product quality.• Led efforts to achieve and maintain certifications such as IATF 16949 or BIQS compliance, demonstrating a commitment to quality and continuous improvement.• Implemented initiatives to improve resource utilization, such as equipment upgrades, scheduling optimizations, or inventory management improvements, leading to increased efficiency and cost savings.• Led the creation of Bills of Material (BOM), Bills of Operation (BOO), and materials specifications for 850 products.• Managed a total of 22,000 BOMs, 6,000 BOOs, and 9,000 materials as Project Manager.• Responsible for managing PPAP and APQP, as well as communication with OEM companies regarding specifications and quality matters.• Responsible for creating and maintaining flowcharts for product processes, conducting PFMEA (Process Failure Modes and Effects Analysis), and developing CP (Control Plans) to ensure product quality and process efficiency.• Conducting capacity analysis and planning to ensure that manufacturing facilities have the necessary resources and capabilities to meet production targets and customer demand.

El Mansoura, Ad Daqahliyah, Egypt

• Developing new technologies or components that improve performance, efficiency, safety, or sustainability.• Leading or contributing to the development of new models from concept to production, meeting project timelines and quality standards.• Implementing manufacturing changes that reduce production costs without compromising product quality or performance, leads to increased profitability.• Identifying and resolving manufacturing issues to enhance product quality, reliability, and durability, resulting in fewer defects and higher customer satisfaction.• Ensuring that designs meet regulatory requirements and safety standards in different markets, facilitating product certification and market access.• Collaborating with cross-functional teams including design, engineering, manufacturing, and testing to ensure the successful integration of components.• Successfully managing R&D projects, including resource allocation, budget management, and risk mitigation, to deliver projects on time and within budget.• Pursuing professional development opportunities to stay updated on emerging technologies and industry trends.

El Mansoura, Ad Daqahliyah, Egypt

• Leading or contributing to the development and launch of new models, meeting tight deadlines, budget constraints, and quality standards.• Developing innovative features, or components that improve performance, safety, comfort, or efficiency, distinguishing the product in the market.• Implementing design optimizations or manufacturing process improvements that reduce production costs without sacrificing quality or performance, contributing to increased profitability.• Identifying and addressing design or manufacturing issues to enhance product quality, reliability, and durability, resulting in improved customer satisfaction and reduced warranty claims.• Leading the development and testing of product prototypes to validate design concepts, functionality, and performance, refining designs based on feedback and test results.• Ensuring that product designs comply with regulatory requirements and safety standards in different markets, facilitating product certification and market access.• Collaborating with suppliers and vendors to source components, materials, or manufacturing services that meet quality, cost, and timeline requirements.• Successfully managing product development projects from concept to commercialization, including resource allocation, budget management, risk mitigation, and stakeholder communication.

El Mansoura, Ad Daqahliyah, Egypt

• Designed, developed, and implemented standard operating procedures (SOPs) and work instructions to establish and maintain consistent and efficient operations across manufacturing processes.• Conducted testing on new materials relevant to the manufacturing process to assess their suitability, performance, and compatibility with existing production methods.• Determine the manufacturing processes needed to produce the new product or implement the redesign. Consider factors such as materials, equipment, labor, and facility requirements.• Develop detailed manufacturing process plans, including assembly sequences, machining operations, quality control measures, and workflow layouts.• Test the manufacturing process with the prototypes, gather feedback, and optimize the process for efficiency, quality, and cost-effectiveness.• Provide training to manufacturing personnel on the new or redesigned manufacturing processes to ensure proper implementation and adherence to quality standards.• Implementing process improvements to enhance efficiency, reduce cycle times, minimize waste, and increase productivity in manufacturing operations.• Leading the development and implementation of new manufacturing processes or technologies to support the production of new product models or components.• Driving a culture of continuous improvement within the manufacturing environment by implementing Lean manufacturing principles, Six Sigma methodologies, and Kaizen initiatives.• Optimizing equipment utilization and reliability to ensure maximum uptime and efficiency in manufacturing operations.• Ensuring that manufacturing processes comply with regulatory requirements and industry standards for safety, environmental sustainability, and quality assurance.• Conducting capacity analysis and planning to ensure that manufacturing facilities have the necessary resources and capabilities to meet production targets and customer demand.

El Mansoura, Ad Daqahliyah, Egypt

• Monitor production line performance to ensure adherence to schedules and quality standards.• Troubleshoot production issues and implement corrective actions to minimize downtime and disruptions.• Collaborate with cross-functional teams including design, quality, and maintenance to ensure seamless production operations.• Analyze production workflows and make data-driven recommendations for process improvements.• Analyze defect data and implement corrective measures to reduce product defects and improve overall quality.• Conduct root cause analysis for production defects and implement preventive measures.• Develop and enforce quality control procedures to ensure products meet or exceed industry standards and customer expectations.• Develop and optimize production processes to improve efficiency, quality, and cost-effectiveness.• Implement lean manufacturing principles and Six Sigma methodologies to minimize waste and reduce process variation.• Conducted trials to determine equipment and machine performance capabilities.• Created engineering documentation for manufacturing processes, equipment specifications, and change notices.• Train production staff on new processes, equipment, and technologies.• Mentor production workers, fostering a culture of continuous improvement and professional growth.