Saudi Iron and Steel / Hadeed - Production Engineer - Rolling Mills - 2/1989 - 2/1998 - =Reported to Coordination Manager, Rolling Mills. Responsible for improvement of yield, productivity, availability, and safety in the Bar Mill, Wire Rod Mill, and Straightening Shop. Defined, and improved, operating variables that restricted rolling speed. Initiated projects, which led to a reduction in delays in the cold shear area. Created a model that showed the impact of cast billet weight variability on yield. improved the design of rebar ribs and bar surface for epoxy coating applications. Led study of shear ring failures which resulted in savings of over $1,000,000 per year. During this period Production availability increased in both of the rolling mills from 65% to over 90%.
Republic Steel / LTV Steel - General Foreman / Manager Total Quality Control - 8/1984 - 2/1989 - Manager, Total Quality Control - Rolling Mills
-Reported to General Manager of Rolling Operations and Director of TQM for the Bar Division. Responsible for coordination of Integrated Process Control (TQM) program for five rolling mills and associated finishing areas. Developed and instructed classes for mill management, supervisory, and hourly TQM process standards, and Statistical Process Control. Led audits of suppliers and internal departments. Supervisory responsibility for departmental IPC Coordinators. Responsible for rolling mills areas involvement in customer audits. Participated in the development of a corporate Repeatability and Reliability program for measuring devices. Participated in presentations for corporate-wide union/management conference on participative management.
General Foreman / IPC Coordinator - Soaking Pits & Blooming Mill
-Reported to the Department Director. Responsible for the scheduling, production, process improvement, and quality of carbon, alloy, and stainless steel bloom product. Represented the department in the assessment of proposals to produce new sizes, and accept new business. Developed computer programs to track major quality parameters, and daily production statistics. Created control charts that resulted in a 70% decrease in "pipe" defects. Suggested the concept for an in-line straightener from spare parts, which resulted in savings of about $10,000 per heat. Direct supervisory responsibility for 4 shift supervisors and 8 foremen. Responsible for establishing statistical process control and developing process standards. Developed a statistical model of ingot weight distribution versus defect risk. Identified a change in the scrap rate through SPC CHARTING that resulted in a savings of about $2 million per year.
Eli Lilly - Business Analyst GBIP Implementation - 8/2002 - Current - -07/2005 - 04/2007 - Member of Production Planning Factory Planning team responsible for design, configuration, and implementation of SAP APO PPDS module and processes for Master Production Scheduling of critical items. Responsible for CIF interface, MRP, Subcontracting scenarios, and Master Data. Rollout to Fegersheim, France
-08/2002 - 07/2005 - Puerto Rico rollout - Member of Manufacturing Operations team responsible design, configuration, and implementation of SAP PP-PI for Production Execution. Developed design for Bulk Manufacturing facility. Led development of first interface with Process Automation system to record Process Order results directly to SAP. Configured PI Sheets. Responsible for design and custom development to enable multiple levels of Production activities to be combined into a single Process Order to support scheduling and reduce order handling requirements. Created functional specs. and coordinated activities with Application Development, QM, and MM to delivery solution. Responsible for knowledge transfer to local support personnel. Responsible for planning assessments, requirement definitions, and gap identification for new sites, and organizing follow up workshops.