Islam Mashaly
Plant Maintenance Manager
Summary
11 years experience in manufacturing field with CSD,NCB ,water bottling lines (Krones-Sidel),Tetrapak lines, salty snacks lines and Biscuits lines in Egypt and Kuwait.
Overview
11
11
years of professional experience
8
8
years of post-secondary education
6
6
Certifications
Work History
Maintenance Manager
KITCO&KBC -Mezzan Holding group
kuwait
11.2021 - Current
- Increase the capacity of C104 PC line By 80 % from 250 Kg/hr to 450 Kg/hr through major Maintenance activities in the line ( Heat exchanger-Fryer-Burner)without any new machine added , with the local maintenance team with cost 1400 KWD.
- Controlled maintenance budgets on a weekly, monthly, and quarterly basis.
- Increase the capacity of C235PC line By 13% from 230 Kg/hr to 260 Kg/hr through troubleshooting for communication issue between fryer and flavor drum which limit the speed of fryer.
- Enhancing product quality in C238 pellet line by modifying control panel (changing Thyristor and B2B for original panel condition )
- Transfer popcorn line to new site ,prepare and modify all utilities required for the line by the local maintenance in 2 days with minimum cost, Relocation of Bites line To Anfal and be the responsible with the OEM to setup the packaging machine and hand-over from them .
- Overhaul and re-operate 3 packaging machine(TNA) weren't in running condition
- Creating preventive maintenance program which reflected on the machine performance, less breakdowns ,greater throughputs Improving 6% in total volume from 2021.
- n order to reduce Mean time to repair (MTTR) ,we Systemize all maintenance work ,All maintenance work conducted through work order form starting from production to maintenance team and include approvals ,making history card for each machine ,and analysis with records for all breakdowns.
- As apart of Maintenance strategy to reduce cost ,reviewing all of our current physical stock, making new lists and prepared list of critical spare parts, fast, slow moving parts and analyzing spare parts usage to reduce inventory cost& keep safety stocks which make us overwrite unused items with more than 20,000 KWD from system and added more than 100 new items weren’t on SAP
- Reducing R&M for machinery by 3% from previous year despite all prices increase, Upgrade machine no 5 due to high repair cost and increase the efficiency by local maintenance , •Restructure the maintenance staff , train the staff ,continue 11 months with manpower shortage in 4 positions and no electricians
Assistant Manufacturing Manager
National canned food,Mezzan holding Kuwait
Kuwait
01.2018 - 11.2021
- Responsible for applying TPM, total productive maintenance culture on the site , In charge of PET 1&2 (poly-Ethylene Terephthalate)water lines , Tetrapak tomatopaste line and Vinegar line.
- performing and monitoring line performance by doing KPI reports on daily basis.
- performing daily internal audit on all lines to assure all production safety standards are being met.
- analyzing and assessing current production methods to be able to design and implement cost -reductive changes
- following production specifications and quality control measures,ensuring all steps of production run smoothly and efficiently.
- studying and determining how many operators needed to man the producton line .
- training,supervising and managing line operators (day and night shifts) in order to maxmize the productivity of the machine operators.
- Diagnosing the roots and causes of breakdowns(including human error)and troubleshooting problems.
- cooperating and planning with maintenance team to maintain equipement for maximum safety & efficiency (applying preventive maintenance).
- following and adhering to company enforced rules and regulations (e.g.HACCP,HSE)
Acting as Productivity &sustainability Manage
PepsiCo
Egypt
03.2017 - 01.2018
- Participate in setting the annual plans and quarterly targets for Plant Key Performance Indicators KPIs.
- Track, support results analysis and development of action plans. Lead the implementation of the Best Practices in operations and environmental fields in the plant
- Coaching through Best Practices refreshment trainings to the site receptors
- Report and Analyze all operations KPIs on PepsiCo’s Global Measure Up system
- Track and analyze monthly plants expenses vs. monthly phasing
- Track resources consumption, Sustainability projects planning & executions
- Conduct performance reviews and audits for operations Productivity and Sustainability
- Support Plant team in analyzing and action planning to ensure continuous improvement for using plant resources.
- Work with plant team to eliminate wastes from the production process
- Leading the implementation of Total Productive Maintenance (TPM) and MMM in the plant
Production Section Head.
PepsiCo
Egypt
01.2013 - 03.2017
- Lead across functional/departmental team to take day to day operational issues and reach shot -and long-term performance goals
- Deliver effective change leadership to drive business changes while minimizing people impact
- Motivate team members to achieve plan goals by having a regular presence on the plant floor
- Applies knowledge of TPM processes, equipment and system capability for individual and facility standards
- Set and achieve performance standards with regards to safety, line utilization and quality
- Track key performance indicators/costs, anticipating and correcting trends which would compromise achievement of financial targets
- Oversees and ensures facility equipment reliability to minimize downtime
- Build people capability through effective employee relations, hiring, training, and communication for front-line hourly personnel
- Ensure compliance with all health & safety regulations
- Administer policies and procedures
Manufacturing Engineer
Sumitomo SEWS-Eg
Egypt
12.2011 - 01.2013
- installation of all assembly machines and setup of the biggest wiring harnesses in the middle east.
- prepared for Toyota global trail build for new Toyota Yaris 2012 model ,Dealing with various Toyota customers in different countries(Yaris in France-verso in Turkey)
Education
High school Dimploma -
Portsaid Military School
01.2003 - 01.2006
Bachelor of mechanical Engineering - undefined
said
university
01.2006 - 01.2011
Skills
Autocad
Accomplishments
- Promoted from production supervisor to production section head at 10 months in Pepsico
- Nominated to represent my plant in PepsiCo operations academy for 30 months .
- Apply my graduation project in PepsiCo OPs academy with cost save reduction 20000 $(350000 EGP)
- Achieve AIB +900 for continuous 4 years
- WON award for achieving best safety rates in work environment in PepsiCo in 2015
- Responsible for applying MMM (management model machine )in my plant and achieve 94% that make my plant start TPM journey.
Certification
Train the trainer, Australian College of Kuwait
Timeline
Maintenance Manager
KITCO&KBC -Mezzan Holding group
11.2021 - Current
Assistant Manufacturing Manager
National canned food,Mezzan holding Kuwait
01.2018 - 11.2021
Acting as Productivity &sustainability Manage
PepsiCo
03.2017 - 01.2018
Production Section Head.
PepsiCo
01.2013 - 03.2017
Manufacturing Engineer
Sumitomo SEWS-Eg
12.2011 - 01.2013
Bachelor of mechanical Engineering - undefined
said
university
01.2006 - 01.2011
High school Dimploma -
Portsaid Military School
01.2003 - 01.2006
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