Marwan

Automotive / Industrial General Manager - Toyota Business Practice Certified
Lean Transformation / Operational Excellence Expert 4

Dynamic, hands-on, Automotive Business Leader with a wealth of knowledge and experience in the automotive manufacturing, Lean Transformation, Kaizen methodology and development. “Continuous Improvement Champion”, cost optimization and waste reduction projects.

Proven expertise in:
• Lean Transformation. “Toyota Best Business Practice (TBP) certified”
• Extensive knowledge of Toyota-Way, problem solving, TBP, QCC, APQP, JIT, 5S
• TPM implementation and visual controls
• Setting the organization's strategic and long-range goals, vision, mission and corporate values
• Extensive knowledge implementing Hoshin-Kanri methodology
• Lead lean transformation projects by continuous training programs, pilot projects and visual awareness
• Setting visual dashboard controls and KPI’s, Obeya room visual data and conducting weekly and monthly meetings
• ISO 9001/14001 & 18001 expert. ISO 14001 lead audit certified
• A3 training programs, problem solving and Kaizen projects presentation and results
• Annual operating plans, manpower requirments and annual cap-budget for the department
• Extensive knowledge in preparing business plans, feasibility studies

• Lean Production system and TPS/TBP certified
• Cost reduction & waste elimination Kaizen projects
• Project Management PMI
• ISO Standards & Auditing Programs
• Kaizen training & development programs

• Risk Management & Mitigation
• SAP(5years)successful implementation
• English, & Russian Arabic Languages
• Motivational team leadership

Professional Experience

Vents – Blauberg Group – Kiev, Boyarka (September 2021 – March 2022)
Lean Transformation Project Manager –
Headed the lean transformation project. Vents is a well-established factory that is producing 20,000 ventilation products (industrial and household)
• Provide leadership/ mentoring/training to all levels of the organization on the use and practice of lean tools (e.g. 5S, visual controls, standardized work, A3, Heijunka, Jidoka, Kaizen and facilitate cross-functional kaizen events.
• Focus on business performance that constantly strives to eliminate waste, improve customer satisfaction, and increase market share via the use of Lean tools and continuous improvement methodologies.
• Drive Lean for methodology and develop appropriate dashboards & influence cross functional team members to meet production volumes and quality KPI’s
• Develop tools and supporting materials, providing training to support the factory initiatives, conducting workshops and other training programs that foster the cross functional deployment of Continuous Improvement Methodology.
• Work with all elements of the business to manage JUST IN TIME concept through supply chain, inventory management, and production control.
• Implementation of four major Kaizen projects in Plastic Injection Plant
• Injection mold allocation system (reduction of waste 60 min -10 min)
• Raw material enhanced delivery to work station (reduction of waste 20 min - 12min)
• Injection Mold maintenance problems liquidation. (reduction of back jobs 200 mold - 75 per month)
• JIT pilot project “ pull system” (successfully finalized the pilot project)

Abdul Latif Jamil Group (ALJ) – Jeddah, Saudi Arabia (2000 to 2019)

General Manager (Toyota Production Plants)

• Implementation of Toyota Production System (TPS) throughout production plants “Toyota Vehicle Customization”. Ramp up production to nearly 32,000 vehicles/monthly.
• Implement lean methodology in all accessory production plants in KSA and Far East Joint Venture Factories.
• Managing vehicle & accessories manufacturing business. Ensuring the achievement of monthly production KPI’s and OEE’s to meet the targeted vehicle sales. Setting an annual budget review for Capital expenditure and manpower calculations. Achieving annual targets of vehicle production of 380,000 (customized vehicles).
• Introduce ISO 9001 /14001/18001 regulatory requirements and drive down non-conformances.
• Developing inline quality inspections processes and implementation of TPM
• Advocate for quality control throughout the production environment. Assemble QCC (quality control circles) that improved installation quality by nearly 99.98%.
• Advocate Kaizen methodology and lean transformation activities that drives quality, continuous improvement, and cost saving initiatives.
• Golden and Silver Kaizen awards for successfully implementing 3 major projects (TPS,JIT and Damage Control).
• Implement “Obeya Room” concepts and run weekly and monthly KPI’s reviews
• Advocate the Hoshin Kanri system and be part of the Toyota Hoshin plans and designed meetings.
• Regularly analyze financial performance of all divisions. Track budgetary spending and reduce unnecessary costs/spending annually.
• Risk Management mitigation plans on annual basis including business continuity strategies.
• Team responsibility: 650 employees
• Achieving annual B2B sales targets 100 million SAR/monthly.

Other projects
• From 2005 - 2007 General Manager for the development of Mobility and conversion vehicles. Conducted a market research and feasibility study for the project. Budget plan and sales forecast and promoting the customized vehicles through dedicated sales centers. The Project was initiated from the scratch and reached revenue of 40 Million (SAR) worth of Sales in three years. Trucks Tipper - Ambulances - Armored vehicles - Refrigerator trucks
• From 2007 – 2008 managed the implementation of the TPS/JIT/ANDON/Pace Control/Kanban systems and coordinated the implementation of Kaizen team activities for production
• From 2008 – 2010 successfully managed the implementation of ISO 9001; 2OOO/ ISO 14001 & OHSAS 18000 for several divisions across ALJ/JACS
• Coaching and setting Kaizen Marathon projects as well as QCC(Quality Control Circles)

Service Manager (Body Shop), 2000 to 2004
Championed all operations for the service center. Developed and implemented all of the strategy, advanced planning, and budgeting activities for the center. Coordinated activities for the after-sales division to directly align goals and objectives with the overall organization’s vision.
Key Contributions:
• Instituted a new first-rate warranty policy that maintained the brand’s position as the number one choice for quality and service in the after-sales market.
• Facilitated technical training to staff, which ensured they delivered the highest quality service and parts to the customer. Improved customer satisfaction scores.
• Designed and released innovative marketing plans for the after-sales division. Improved overall divisional performance and revenue.
• Established monthly sales and revenue performance targets for the division. Incrementally improved performance to over 1M SAR of total sales.
Sayegh Group & National Paints Factories Co. Ltd. – Amman, Jordan
Production Manager
Century Investment Group – Amman, Jordan
Production Manager
EDGO Management Group – Amman, Jordan
Project Manager
Odeh Naber Transportation Company – Amman, Jordan
Machine Shop Manager

Education and Certification
Master’s Degree in Machine Building Technology
Kirovograd Machine Building Institute, Ukraine

Training

• Welding Technology – Royal Society for Sciences – Amman - Jordan
• Toyota Way - (TMC) – ALJ Training Centre - Saudi Arabia
• Introduction to ISO 9001,14001, 18001 – SAPCO Group
• Internal Audit Training – SAPCO Group
• Great Managers Program – Gallup - ALJ Training Centre- Saudi Arabia.
• Achieving your Highest Priorities – Steven Covey – ALJ Training Centre- Saudi Arabia.
• Seven Habits of Highly Effective People – Steven Covey – ALJ Training Centre- Saudi Arabia.
• Presentation Skills - ACCL- ALJ- Training Centre- Saudi Arabia.
• Free Zone Thinking for Innovation Techniques (Mat-thys Fourie & Dr Chalres Kepner)
• Leadership Techniques – ACCL
• Business Objects Course - ACCL
• Strategic Planning – ACCL
• Balanced Scorecard Training - ACCL
• PMI – Project Management Professional – ACCL
• Certification of Entrepreneurship – Cornell University (KAUST-)King Abdullah University of Science and Technology
• Certification – Effective Strategic Supply Management – Purchasing & Procurement Center, Inc.
• Mini-MBA Purchasing & Procurement Centre Inc.
• Fundamentals of Risk Management – Institute of Risk Management.

Certifications
• Certified TBP expert (Toyota Business Practice), coaching and setting QCC(Quality Control Circles)
• Certified TBP expert (Toyota Business Practice), coaching and setting Kaizen
Marathon projects
• Certified ISO 14001 Lead Auditor Training – Bureau Veritas
• Kaizen Awareness Program( KAP) – Continued commitment for Kaizen though completing KAP-1 - “ Kaizen & TPS, Circle of Trust & 5S Philosophy
• Certified ISO 14001 Lead Auditor Training – Bureau Veritas

Appreciations
• Certificate of Appreciation – Brand Champion, Delight Associates, Delighted Guests.
• Recognition Letter- continuous commitment to Toyota Way through continuous improvement and sharing the opportunities of development and maximizing individual and team performance.
• Appreciation Letter – for the outstanding performance & sustainable contribution to 2008 – 2009 Kaizen Marathon Activity
• Appreciation Letter – for the outstanding performance & sustainable contribution to 2010 Kaizen Marathon Activity.
• Certificate of Appreciation – In recognition of the valuable and outstanding performance of Port Installed option Centre - JACS