Mohamed Khafagi

Experience

• 

  Mondelēz International

  Apr 2014 - Jun 2020

   Responsibilities: • Leading all sugar gum making agenda for the site with a team of 60 employees through 3 shifts.• Leading Autonomous Maintenance implementation as pillar lead for the site from step 1 to step 6. • Coaching for six sigma systems for the site: Abnormalities handling, Cleaning Inspection Lubrication, Daily management system, and Centre lining.• Lead the first workload analysis for flavours preparation team. Calculation the workload and coming up with initiatives to optimize workload.• Supporting products optimization projects for gum processing: Global Clorets recipe homogenization working with R&D team.  Key Achievements: • Supporting site leadership team in annual budget creation with tailored excel worksheets to dynamically calculate required overtime annually divided into months. • Achieving 86% in QCMS audit performed by global auditing team, One of the highest scores globally and with zero observations for the process section. • SAP key user for the site and materials losses work process owner. Achieving 0.7% material yield loss the best globally coming down from 3%. • Planned and executed pre-production and storage of 80 tons to avoid plant stoppage during process line upgrade which prevented the loss of 40MEGP to the business in the volume drop. Show less  Responsibilities: • Leading 3 packaging lines with a team of 60 employees. Leading the production of Clorets & Chiclets gum brands. • Working with planning team to optimize production runs and achieve repeated frequency plan. • Optimization opportunities to achieve the continuous waste elimination throughout all the packaging lines.• Supervise and coach technical personnel, regarding the IL6S and process training in the AM pillar as well as coordinating with other pillars (PM, FI, QM, HSE)  Key Achievements: • Improved lines performance from 65% to 91% through successful implementation of AM steps 1 to 5. • Working with packaging materials suppliers in improving the quality of packaging materials. • Achieved the highest score across all Mondelēz International sites globally in Integrated Lean Six Sigma Phase 1 assessment with a score of 88%. Show less  Responsibilities: • Leading maintenance agenda of 6 production lines with a team of 10 technicians. • Planning for preventive maintenance for the packaging lines to sustain performance. • Developed center lining standard for the site which increased lines performance and consistency.  Key Achievements:• Successfully passed phase 0 audit for Integrated Lead 6 sigma. • Achieved savings of 900 KEGP in 2016 from the maintenance budget. • Leading the implementation of Progressive Maintenance steps 1, 2, and 3 for all packaging lines.• Achieved breakdowns percentage of 1% during 2016 for packaging department coming down from 2% during 2015 and 12% during 2014. Show less  Responsibilities: • Leading qualification and verification process for the Trident Singles line. • Leading 4 SKUs trials and final recipe confirmation with R&D. • Successfully collaborated with Business Development and R&D teams for pre-production trials and line startup.  Key Achievements:• Developing and implementing training plans for the core team to develop operation skills to create 3 shifts crew out of initial team of 6 operators. • Leading performance analysis task force increasing the line’s efficiency from 60% to 81%• Leading the first SMED exercise in the site for product change over and successfully decreasing change over time by 88% from 8 hours to 1 hour. Show less  Responsibilities: • Leading maintenance agenda for the site with a team of 11 technicians plus 6 contracted technicians from Johnson Controls for HVAC systems. • Managing maintenance budget of 2.9 million annually. • Planning for preventive maintenance for the lines to sustain efficiency. • Spare parts management: stock monitoring and creating purchase requests for spare parts. • Follow up with external suppliers for spare parts, new tools delivery and required contracting jobs. Key Achievements: • Successful coordination and implantation for relocation project for 7 packaging lines and 1 process line to new site. • Full refurbishment for Trident line using 100% local spare parts. • Complete reevaluation and tagging for all site assets to prepare for sale. • Coordination with procurement team for external visits for buyers to finalize assets sale. Show less

  • Process Section Lead - Autonomous Maintenance lead

    Oct 2018 - Jun 2020

  • Packaging Section Line Leader

    Aug 2016 - Oct 2018

  • Packaging Section Maintenance Engineer

    Apr 2015 - Nov 2016

  • Vertical Start up Engineer - Trident Singles Line

    Apr 2015 - Jan 2016

  • Site Maintenance Engineer

    Apr 2014 - Apr 2015
• 

  Beyti - an Almarai Subsidiary

  Jun 2020 - now

  •Production Optimization and Resource Planning:-Collaborated closely with the supply chain team to lead daily and weekly production planning for 17 production lines across 2 sites. -Strategically planned and allocated manufacturing resources throughout the year, including fixed and casual workers, machine utilization, and processing equipment (such as pasteurizers, mixers, and tanks).•Performance Management and KPI Tracking:Developed comprehensive 360-degree scorecards that tracked daily, weekly, and monthly Key Performance Indicators (KPIs) for the manufacturing process.-Ensured seamless operations by planning and executing periodic maintenance and shutdowns in collaboration with all stakeholders, without compromising delivery schedules.•Inventory Optimization and Capacity Enhancement:-Collaborated with the Sales & Operations Planning (S&OP) team to optimize stock levels while maintaining adequate working capital.-Worked closely with the engineering team to identify and address capacity constraints within the processing system, ensuring smooth operations.•Shared Equipment Planning:-Strategically planned the utilization of shared processing equipment between different product categories (fresh and UHT) during seasonal variations.•SAP Expertise and Financial Compliance:-Served as the SAP key user for the site, leading daily and weekly analyses by the SAP team to ensure compliance with budgetary constraints and targeted savings.-Responsible for all manufacturing reporting, from daily production updates to losses reports, and participated in monthly reviews with the CEO and functional directors.•SAP Application Review and Enhancement:-Developed a detailed timeline plan to achieve full compliance with SAP processes, including support for the (Extended Warehouse Management) module implementation.-Initiated (BOM) revision for all 2000 SKUs,-Successfully reduced material losses from 2.5% to 1.7%,-Optimized casual labor spending, achieving a 17% reduction. Show less Responsibilities: • Leading the manufacturing of Almarai Milk brands with daily capacity up to 500 tons/day. Leading 3 shifts on operate and maintain model. • Planning for required manning and casual labour using different running scenarios with supply chain team to fully optimize operation according to projected demand. • Leading performance task force for Krones line using lean six sigma methodologies to tackle top losses: DMAIC, root cause analysis, small group activities, Daily management system, and Waterfall analysis. Key Achievements: • Optimized production runs with planning and processing team and were able to increase daily processing output from 250 tons to 420 tons. • Achieved 950 score in AIB external unannounced audit. The highest ever in all Almarai sites globally. • Achieved year-on-year cost per ton reduction by 20% by tackling material losses in production and maximizing line output, which resulted in 30% volume growth versus last year. • Created the annual budget for chemicals and casual labours for the site with production managers with detailed spending targeting 10% savings through optimization projects and loss elimination in CIP chemicals. Show less  Responsibilities: • Leading all Foods manufacturing agenda with a team of 55 employees through 3 shifts, 7 yogurt and drinking yogurt lines. Responsible for processing and filling. • Creating and coaching on Safety standard for all foods operators and engineers to insure zero incidents • Initiated Daily management system in Foods to optimize daily activities and short-term action plans.  Key Achievements: • Increased production efficiency of drinking yogurt line from 58% to 75% through six sigma analysis tools: Root Cause Analysis with engineering team. • Successfully passing AIB external audit with 900 score. • Successfully implemented production runs extension project up to 72 hours with quality team resulting in increased overall capacity by 5%. • Created change over procedure between all SKUs with accurate identification of mix phase to eliminate any need for manual verification and minimize material losses and defected products.• Lead the project of Zero Losses for materials in process resulting in decreasing material losses from 2.1% to 0.89% leading to 6 million EGP cost avoidance annually. • Achieved a year-on-year growth during the Ramadan 2021 Season by 30%. Double the usual during previous years. Show less

  • Plant Productivity Manager

    Mar 2022 - now

  • Production Manager - BP2

    Jul 2021 - Mar 2022

  • Food Production Manager

    Jun 2020 - Jul 2021