RACHID E.
SENIOR LEAN SIX SIGMA BLACK BELT, SOHAR ALUMINIUM
SOHAR ALUMINIUM Sohar, Sultanate of OMAN
Senior Lean six sigma Black Belt
1540 employees, 800M$ Revenues
Company profile:
The newest addition to the Middle East's metals circuit and Oman's first foray into the Aluminium industry, Sohar Aluminium has been breaking records since its inception.
By implementing decades of industry insight in its design, specification and construction Sohar Aluminium has been created to ensure efficiency, environmental protection and the utmost safety of its workforce. Noteworthy examples include the world's longest single pot line, the world's highest known capacity ingot casters and innovative elevated walkways traversing the entire site to keep man and machine separate except when absolutely necessary.
SOHAR ALUMINIUM AWARDED HIS MAJESTY’S CUP FOR BEST 5 FACTORIES IN OMAN
199 contactsResponsibilities:
• Train Green belts candidates on lean six sigma tools
• Coach Green and Black belts candidates (10 people)
• Prepare a new PPS (Practical Problem Solving) training material
• Provide PPS training supervise PPS projects
• Introduce new lean six sigma standards (project templates, project follow up..)
• Introduce a new project selection tool
• Help to build a plant wide projects pipeline
• Facilitate kaizen workshops
• Report all project savings
• Conduct transactional and manufacturing LSS projects
• Audit ESH system
• Manage project documentation
Achievements:
Examples of projects conducted:
• Pot Tending Assembly Performance and Service Enhancement
• Reduce breakdowns from 17 to 10/day
• Improve interaction between maintenance and reduction
• Reduce the spare parts consumption.
• Use advanced statistical tools to take decisions
• Other projects or Kaizens linked to HR, Finance, Supply chain….
• Improve the Current Efficiency of Aluminium Reduction Department (on going)
Several millions of $ as savings expected
2006 - 2011Positions: Lean Leader (2009)
Lean Six Sigma Black belt (2007-2009)
Lean Six Sigma Engineer (2006-2007)
Implement Lean Six Sigma tools and the culture of change in the plant
Co-ordinate with European plants lean leaders to share best practices
Conduct technical training (air and hydraulic)
Conduct Green belt and Lean Six Sigma fundamentals training
Conduct transactional and manufacturing projects.
Examples of projects conducted:
Put in place a new layout in assembly area
Reduce inventory inside the cell by 300Keuros
Improve the flow
Increase the capacity by over 20%
Reduce workers travel distance from 10metres to 2 metres
Implementation of a new test bench
Increase the capacity by over 20%
Headcount reduction by 30%
Exp of projects conducted as black belt :
Delivery Lead time reduction, Phase 2 cost reduction,
inventory reduction..
Other projects:
Implement Total productive maintenance TPM,
A3 Strategy deployment, VA/VE on major models ...
- I have established the requirements and set up the ‘Complete vehicle quality system ‘.
- I have been in relation with the other European plants for the solutions standardization.
-I have designed a tool aiming at improving the time limits for
production processes and monitoring the queue
- I have trained planners in the queue-controlling software
-I have set up a new working organization based on Valeo
Production System concepts and the Design For Assembly (DFA)
- Workstations balancing