Personal information

Name: Amr Aly Abdel-Halim Mohamed

Email: amry14@aucegypt.edu

Telephones: 2-01006593856 or 2-015- or 2-03-5453938

Birth date: 4/5/1980

Marital status: married

Objective To obtain full time job in the field of quality/organizational excellence management

Education and certificates

Bachelor of Science, American University in Cairo, Spring 2004 Major:

Mechanical engineering

Specializations: Industrial Engineering, and Materials and Manufacturing

Cumulative GPA: 3.15/4

Study abroad: Studied engineering at Pennsylvania State University,

State College for two semesters as part of the exchange program with the

Unites States universities May 2001. Co-operative education at Dana

corporation Nov 2001 in Reading Pennsylvania (attached).

Vocational certificates:

1- Six Sigma Green belt at the American University in Cairo certified by

Quality America, 2008

2- Internal auditor IS0 9001, 14001, OHSAS 18001 from BSI, 2011

3- 4Q ( ABB improvement methodology) certified, 2012 (project was a

must)

4- Lead auditor ISO 9001 from Intertek Moody, 2013 approved by IRCA

5- Total Quality Management TQM, accredited from ILM, UK, 2013

6- Certified Manager of Quality and Organizational Excellence

CMQ/OE from the American Society of Quality ASQ, Oct. 2013

7- Black Belt Lean Six Sigma from ASQ, 2014

8- ABB Operational Excellence Program (OEP); First session in

Germany; Dec 2014.

9- 4Q train the trainer coach in Zurich Oerlikon Feb 2015

10- ABB Operational Excellence Program (OEP); second session in

Spain; Mar 2015.

Job recognition My Six Sigma (4Q) project was chosen among the best six projects in ABB

India, Middle East and Africa region in 2012

Current job/part time/Global roleFeb 2015- Now

-Global Business Unit/PPMV Expert for Improvement projects, cost of

poor quality and Top 5 quality:

1- Support and advice for solving Opxanalyzer issues

2- Consult for cost of poor quality capturing

2- Coach and advice for 4Q/Six Sigma methodologies for top issues projects

3- Support in improvement of Opx-analyzer tools in terms of data collection

and reporting features

Current job/full timeFeb 2013- Now

- Operational Excellence Specialist for PPMV Business Unit (BU) Egypt-

Started in Feb 2013 (Previously worked as Quality Engineer)

- Job description:

1- Lead business unit team to meet operational excellence targets (RELEX:

ROTD, Inventory, Cost of Poor Quality and cost saving, NWC%,

Customer sites issues)

2- Lead the Manufacturing and Operational excellence maturity assessment

tool and the action plan for increasing the Operational Excellence

(OPEX) maturity level

3- Raise the awareness of Cost Of Poor Quality (COPQ) elements among

the BU team to make COPQ more visible and make awareness of the

COPQ elements definitions.

4- Follow up of Top 5 Quality issue projects (Raise and prioritize of issues,

coach of projects)

5- Lead Six Sigma (4Q) workshop for major KPI.s like On Time Delivery

issues

6- Generate cost saving projects from cost of poor quality/OPQ and

brainstorm with business unit team for new cost saving projects

7- Train and coaching on Six Sigma (4Q) methodology

Achievements 1- Coached 4Q FAST event in LV assembly area:

A) Reduced material stock by 40%

B) Increase the number of products that can be assembled at the same

time by 42%

C) Reduced excess motion

D) Remove more than 75 material items as excess material

2- Improve the cost saving per year by 55% in 2 years

A) Improve COPQ capturing created more opportunities for saving

B) Motivation of PPMV team to generate and record cost saving ideas

through ABB recognition policy

C) Training on improvements methodologies 4Q/six sigma

3- Increased the capturing/visibility of COPQ. COPQ % is now 8.5%

compared to 3.5% in one year

A) Make simple templates for OPQ recording

B) Record all lost opportunities

C) Understand relationships between different KPI.s

D) Learn about other accounting systems

E) Consult specialists

4- Led major Six Sigma (4Q) projects (On Time Delivery, Under-

absorption, After sales cost)

5- Coach of 4Q/Six Sigma projects (Customer top issue, Internal defect

rates, Product issues and product recall, Margin Slippage, Supplier top

issues, Inventory reduction and Overtime reduction)

6- Improve data accuracy for Operational excellence KPI.s : Audit and

examining

7- Improved the operation and manufacturing maturity level from level

1.5 to level 3:

A) Awareness to the team of key tools in the Maturity assessment tool

(TPM, 5S, Gemba, Theory of constraints, Skill matrix, process control

and CTQ.s, One piece flow, Value stream mapping)

8- Improved the opx-analyzer tool on the global level as I was selected

to be part of the global team releasing the new version

A) Improved COPQ collection by identifying improvement opportunities

in a better and more systematic way by making the reporting to be in

a detailed level.

B) Added new COPQ items into the tool (in progress- approved by the

global team).

Local trainer and coach on 4Q/Six Sigma tools2014-Now

1- Trained 2 waves of Six Sigma (4Q) basic training

2- Coached 11 Six Sigma (4Q) projects

Internal Auditor 2011-Now

Performed 15 internal audits on safety and environmental systems and

7 on Quality system with clear objective evidence and constructive

feedback for improvement.

Performed gap analysis on the service business in OHSAS 18001.

Current job2July 2008-Now

Quality and Testing Engineer, ABB Egypt (Power Products-Medium

voltage), Areas of experience (products):

Previously: Compact Secondary Substations , Secondary Switch Gear

Now: Apparatus (Load Break Switches, Circuit breaker, and Transformers)

- Job description:

1. Leading improvement teams for continuous improvement of quality

indicators (e.x FPY%, DPU)

2. Lead RCA / CA / PA activities to drive process control at the cross

functional level

3. Develop and lead action plans to resolve customer and plant supplier

quality issues, and to fix problems by implementing permanent corrective

actions. 

4. Lead cost saving (Six Sigma) projects

5. Construct and maintain control charts for process parameters

6. Assures the control of production processes during in process and final

stages

7. Drive continuous improvement of supplier quality, and delivery

performance by working closely with cross-functional teams to deliver key

consumer quality CTQs

8. Conduct Quality, Environmental, Safety audits

9. Train team on quality tools

Achievements1. Identified critical to customer items and made control plan for the

corresponding critical to quality.

2. Implemented the plan do check act methodology for the continuous improvement of the product quality.

3. Six Sigma (4Q) project (chosen to be presented in the region (IMEA)

quality meeting among the best 6 projects in the region) : Made a saving

of about 0.2 million $/year by improving supplier quality (Tools used:

Pareto analysis, Control charts, Hypothesis testing, 5 Why.s analysis,

SMART actions, Mistake proof practice)

4. Improved manufacturing quality: First Pass Yield from 65% to 75% (Tools

used: Pareto analysis, data classification, 5 Why.s Analysis, Fish-bone

analysis, Brain storming, SMART actions, mistake proof practice)

5. Led the cross-functional team to implement 38 corrective actions in 5

months

6. Made the quality process procedure and flow chart- TQM project

7. Improving the Cpk of the product (Load break switch) open speed from -

0.48 to 1 and it is still under improvement

8. Trained blue collar labors on six sigma tools with practice on actual

problems

9. Performed 12 internal audits on safety and environmental systems and 4

on Quality system with constructive feedback.

Previous job1July 2008-July 2009

Industrial Engineer, ABB Egypt (Power Products, MV)

1. Design of Kanban system

2. Design of new factories layout using AutoCAD

3. Work study, flow process charts

4. Simulation of industrial operations

5. Making of Standard Operation Procedures (SOP)

Achievements 1-Made Standard Operation Procedures (SOP)

2-Reduced material inventory by implementing the Kanban System

3-Improved working environment by changing assembly line layout

4-Made flow charts showing the percentage of value added steps

Previous job2Jun 2005 – July 2008

Kama SteelFlat steel

Process engineer

Job description:

1. Work study and simulation modeling analysis of industrial operations

2. Feasibility study of new investments including technical assessment

3. Problem solving of major problems by the aid of statistical analysis

such as Regression Analysis and Hypothesis Testing

4. Improve process by using Six Sigma tools (priority matrix, FMEA)

Achievements 1. Cost-saving of 0.5 million $ by improving the manufacturing method

2. Reducing operation time by 20 % by improving the manufacturing tools

3. Made work instructions to avoid major grinding defect

4. Motivate labor by establishing incentive system based on two dimensions

(Quality and productivity)

5. Made analysis for major line stoppage incidents based on six sigma

methodology

6. Selection of best manufacturing solutions using FMEA method

Previous job3Jun 2005 – July 2008

IBCBAAN software

ERP Consultant

Job description:

1- Implement ERP system to improve clients' manufacturing systems

2- Train clients on ERP system and its tools

Achievements 1- Supported 2 major ERP projects (home appliances, Methane gas

processing)

2- Innovated new ERP solutions

System simulation Consultancy

FlexsimsoftwareNov 2011-Now

System modeling consultant

Job description:

1- Train clients on flexsim basic modeling course

2- Offer consultancy for industrial and non-industrial modelling solutions

using flexsim

Achievements Training achieved:

1- Training of Basic flexsim course to PHD student in British university

2- Training to furniture technology team in Ministry of industry

Projects achieved:

1- Modeling of passenger flow in Cairo Airport

2- Optimization of profit of manufacturing facility

3- Reducing 35% of material handling by labor in car seats local factory

Vocational

Trainings

Statistical Process Control (SPC):

1-Learned the Statistical Distributions and its applications

2-Learned Regression Analysis, control charts, and Design of Experiment

(DOE) and its applications

SPC using Minitab software (Simpious):

1-Learned about the main statistical tools of Minitab

Leading bold change:

1- Learned the 8 steps of making a desirable change through the story of

"Our iceberg is melting"

2-Practiced the eight steps with the class team

OHS Trainings:

1-Risk assessment

2-7 steps for electrical hazards

3-Safety Observation Tour (SOT)

4-Stop take 5

Technical training:

1-Load break Switch Assembly (ABB Poland 2010 and 2013)

ISO 9001, ISO14001, OSAS 18001 training (12 days- BSI):

1-Awareness training on all requirements

2-Training on internal audit techniques

References ABB references:

1- Carlos Pettinau, PPMV global OPEX manager, x-PPMV LBU in Egypt

2- Abdou El-Bortokally, x-Quality manager, PPMV in Egypt

(contacts available upon request)

3- Steven Hegyi, x-General operation manager, PPMV in Egypt

Sports 1- Playing Tennis 2- Basketball