Wael Zain
Spring,USA
Summary
Accomplished Production Planning and Optimization Manager with a proven track record at Integra Mission Critical, enhancing production efficiency by 25% through lean manufacturing and process engineering. Skilled in data analysis and project management, I excel in leading teams to surpass objectives while maintaining high-quality standards. Expert in ERP systems and fostering a culture of continuous improvement.
Overview
14
14
years of professional experience
1
1
Certification
Work History
Production Planning and Optimization Manager
Integra Mission Critical
Houston, TX
10.2024 - Current
- Develop and maintain production schedules to meet customer demands.
- Analyze demand forecasts, and adjust production plans accordingly.
- Identify inefficiencies in production processes, and propose improvements.
- Implement lean manufacturing techniques to reduce waste, and enhance productivity.
- Create an impact assessment project in the assembly area.
- Develop an impact assessment plan for projects, and initiate Kaizen events across multiple departments to enhance efficiency and reduce downtime.
MANUFACTURING SPECIALIST/INDUSTRIAL ENGINEER
Baker Hughes Company
Houston, TX
03.2022 - 09.2024
- Implemented lean principles across value streams; lean certification is highly desirable.
- Data Analysis, ERP Systems, and Root Cause Analysis.
- Process Engineering and Lean Manufacturing.
- 5S and Six Sigma Green Belt
- Process Improvement and Supervising Experience
- SAP, MRP, Quality Assurance, QA/QC, CNC, Supply Chain.
- Production and Project Management.
- Microsoft Office.
- Monitored and reduced process costs while reviewing and managing work order expenses.
- Create, update, and implement routing and BOMs that impact manufacturing and quality issues.
- Conducted root cause analysis on process issues to determine corrective action plans.
- Provided technical support during new product launches.
- Developed standard operating procedures for each production step.
- Developed and implemented manufacturing processes that improved production efficiency by 25%.
- Reviewed and approved ECOs affecting inventory, production, and product lifecycle.
- Applied 6 Sigma lean tools to individual departments to enhance cost reduction, quality, safety, and ergonomics.
- Improved process cycle time by searching for new technology and tools.
- Assisted in managing labor hours and costs, and collaborated with finance to track project success metrics.
- Support on layout study, optimization, and finalization.
- Complete the production plan by scheduling, establishing priorities, monitoring progress, and resolving problems.
- Researched emerging technologies that could be utilized within the manufacturing process.
- Conducted statistical analysis of quality data to identify areas for improvement.
MANUFACTURING PROCESS ENGINEER
Boomerang tube, LLC
Houston, TX
05.2019 - 12.2022
- Optimized existing production processes through root cause analysis and corrective action plans
- Reduced setup time on 5-axis machines from 45 to 15 minutes by implementing fixtures and magnetic tables
- Enhanced Mori-Seiki lathe machines by replacing manual shocks with hydraulic systems, improving safety for operators
- Time study of products to eliminate costing and tooling
- Review production schedule, engineering specification, process flow and other information
- Utilized ERP/MRP systems (MAS 500, Global Shop) to manage products, and update routers and bills of materials
- Create procedures and work instructions for each process in the plant
- Troubleshooting manufacturing issues and implement solutions
- Maintain organization's safety forms record and update them as required
- Responsible for monitoring and controlling documents including welding summary, punch list, reinstatement, circuit blowing
- Prepared hydro test packages and method statements, conducted pre-test inspections, witnessed tests, and validated post-reinstatement of systems
- Ensure that all construction activities conform to the construction codes, specifications, standards and drawings
- Reviewed engineering drawings, specifications, and test protocols to ensure accuracy of products
- Conducted technical analysis, evaluation, and testing to resolve quality-related product issues and performed root cause analysis on defective components to identify potential failure sources
- Identified non-conformances during incoming material inspections and initiated corrective actions
- Plan and strategize the work plan for the Piping department based on the overall project execution plan and strategy
- Responsible for establishing, promoting and maintaining a safe and hazard free working environment
- Supervised work activities to ensure compliance with quality norms and project specifications, and led the team for timely and accurate execution
- Contributed to project planning and scheduling, defining project milestones for timely completion
- Documented project progress and developments to maintain clear and transparent communication with stakeholders
- Managed engineering projects efficiently, meeting deadlines and adhering to budget constraints
MANUFACTURING PROCESS ENGINEER
Southwest Oilfield Products
Houston, TX
12.2014 - 04.2019
- Reduced setup time on 5-axis machines from 45 to 15 minutes by implementing fixtures and magnetic tables.
- Enhanced Mori-Seiki lathe machines by replacing manual shocks with hydraulic systems, improving safety for operators. Time study of products to eliminate costing and tooling.
- Review production schedule, engineering specification, process flow and other information.
- Utilized ERP/MRP systems (MAS 500, Global Shop) to manage products, and update routers and bills of materials.
- Create procedures and work instructions for each process in the plant.
- Troubleshooting manufacturing issues and implement solutions. Maintain organization's safety forms record and update them as required.
QUALITY ENGINEER
Saipem
Algeria
04.2011 - 07.2013
- Responsible for monitoring and controlling documents, including the welding summary, punch list, reinstatement, and circuit blowing.
- Prepared hydro test packages and method statements, conducted pre-test inspections, witnessed tests, and validated the post-reinstatement of systems.
- Ensure that all construction activities conform to the construction codes, specifications, standards, and drawings.
- Reviewed engineering drawings, specifications, and test protocols to ensure the accuracy of products.
- Conducted technical analysis, evaluation, and testing to resolve quality-related product issues, and performed root cause analysis on defective components to identify potential failure sources.
- Identified nonconformances during incoming material inspections and initiated corrective actions.
PIPING CONSTRUCTION ENGINEER
Saipem
Algeria
10.2010 - 04.2011
- Plan and strategize the work plan for the Piping department based on the overall project execution plan and strategy.
- Responsible for establishing, promoting, and maintaining a safe and hazard-free working environment.
- Supervised work activities to ensure compliance with quality norms and project specifications, and led the team for timely, accurate execution.
- Contributed to project planning and scheduling, defining project milestones for timely completion.
- Documented project progress and developments to maintain clear and transparent communication with stakeholders.
- Managed engineering projects efficiently, meeting deadlines and adhering to budget constraints.
Education
MASTER'S IN WELDING ENGINEERING TECHNOLOGY - INDUSTRIAL ENGINEERING
International Institute of welding
Egypt06.2010
BACHELOR'S IN MECHANICAL ENGINEERING - MECHANICAL ENGINEERING
Hims University
Syria05.2008
Skills
- Data Analysis
- ERP Systems
- Root Cause Analysis
- Process Engineering
- Lean Manufacturing
- 5S
- Six Sigma Green Belt
- Process Improvement
- Supervising Experience
- SAP
- MRP
- Quality Assurance
- QA/QC
- CNC
- Supply Chain
- Production
- Project Management
- Microsoft Office
Certification
Six Sigma Green Belt
References
References available upon request
Timeline
Production Planning and Optimization Manager
Integra Mission Critical
10.2024 - Current
MANUFACTURING SPECIALIST/INDUSTRIAL ENGINEER
Baker Hughes Company
03.2022 - 09.2024
MANUFACTURING PROCESS ENGINEER
Boomerang tube, LLC
05.2019 - 12.2022
MANUFACTURING PROCESS ENGINEER
Southwest Oilfield Products
12.2014 - 04.2019
QUALITY ENGINEER
Saipem
04.2011 - 07.2013
PIPING CONSTRUCTION ENGINEER
Saipem
10.2010 - 04.2011
MASTER'S IN WELDING ENGINEERING TECHNOLOGY - INDUSTRIAL ENGINEERING
International Institute of welding
BACHELOR'S IN MECHANICAL ENGINEERING - MECHANICAL ENGINEERING
Hims University
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