Ahmed Mohamed Badr

QA & Safety Manager at French Lubes Blending Plant

76 Samoha, Alexandria – EGYPT

Mobile: (+2) 01020086774

Home Phone: (+2) 03 4268052

E-Mail: ahmedbader260@hotmail.com

Career Objective

A dedicated professional with 10+ years of expertise in the manufacturing of lubricants, with keen proficiency in production & operations management, laboratory and R & D activities, cost control, materials balancing, safety management, quality control and quality assurnace domains.

Key Skills

Blending process management. Pilot blends processing & formulations validation. Cost control. Reconciliation & materials transactions (manually and on SAP software system). Laboratory analysis & QC inspections. Safety management. ISO series certification process & internal auditing (ISO 9001, OHSAS 18001 & ISO 14001). Data analysis. Production & Supply planning (enhancement).

Education

BSc of sciences in chemistry, Alexandria University, the grade is good & graduated in 2004.

Professional Experience

French Lubes Blending Plant (July 2005 till now).Position: QA & Safety Manager in Lubricants Operations Department,(October 2012 till now).

Responsible for ISO series certification process of the plant (ISO 9001, OHSAS 18001 & ISO 14001). Established the operational & quality procedures as well as safety procedures, with reference to ISO

9001, OHSAS 18001 requirements and the group guidelines standards. Responsible for planning & conducting steady and random internal audits, reporting the results to the

Plant managment, lead all team members to recommend appropriate corrective & preventive actions to eliminate the cause of non conformity.

Being responsible for the monthly review of supply & production plans, comparing their records versus forecasted volumes & actual produced quantities during previous periods as to ensure the accuracy of planning process.

Contributed in the technical selection of new laboratory devices to enhance the capability of laboratory to perform all essential analysis (automatic viscosity, CCS, automatic flash point).

Main Achievements Obtaining the ISO 9001 certificate from TUV Rheinland in 2014. Passing 4 internal audits from the group with the least observations & non conformities (technical &

process audits). The preparation of prevention plan to cover an extension project for fiiling lines & dispatching facility. Participation in the analysis of correlation samples after laboratory development.

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Position: HSEQ Supervisor in Lubricants Operations Department (May 2010 till October 2012).

Constantly developed several combinations of base oils for each product in order to achieve determined budgeted volumes, recommended the optimum formulation to be applied within blending scope of lubricants as to obtain the maximum possible margin.

Analyzed previous quality history including received customer complaints as to update and develop the applied procedures & QC plan, coordinated with all team members for effective implementation of newly determined measures.

Supervised laboratory & QC inspections among raw materials receiving process, intermediate products processing, filling activities, storage & dispatching operations, in integration with agreed actions arising from suppliers assessment as well as planned visits of service stations.

Was responsible to communicate with base oils suppliers concerning oil-specific technical defects, supporting such communication with obtained analysis results at laboratory (proactive control).

Managed new design verification & validation steps with involved departments as a part of the marketing plan to launch any new packaging material.

Participated in the preliminary phase of SAP software program regarding stocks cleaning by introducing slow moving products as a rework in the blending combination of running products.

Was responsible for introducing the blending orders onto the SAP software system and reconciling between blended quantities, filled quantities and raw materials stocks (physical & actual stocks).

Managed to enhance personnel contribution at all levels to near-misses, incidents & accidents reporting, moreover, supported the implementation of associated CAPA by conducting steady sessions for enhancing the awareness, aiming to improve the quality of presented information as well.

Developed the emergency plan and well communicated its parameters to all personnel, planned sudden drills as to examine the readiness in emergency cases (personnel attitude & responding time).

Updated the risk assessment study which was the basis to well train the staff on critical tasks and related corrective & preventive norms.

Prepared the annual plan for inspecting the fire fighting system & followed-up its implementation as per schedule.

Main Achievements 20 % increase in the number of valid formulations (50 formulations). 12 % increase in the overall margin. The annual rate for received customer complaints decreased gradually from 12/ year in 2007 until

being zero in the year 2011. Introducing 30 MT of final products piled stocks in the new processed blends (recycling instead of write

off). Lunching new package after facing problem in material selection as well as the unequal distribution of

raw materials that led to weaken the thickness in many measured points. Decreasing the variance between consumed raw materials and produced volumes from 0.6% to

around 0.18%.

Position: Blending and Laboratory Supervisor in Lubricants Operations Department (July 2005 till May 2010).

Supervised the inspection of raw materials, in-process & final products and reported obtained analysis results to help the decision making among supplying & storage processes.

Participated in the structuring of operational procedures & QC plan and supported their effective implementation within laboratory domain.

Established a control tool to monitor the products cost & recommended the optimum formulations to be applied within blending scope, continuously introduced new combinations as to achieve the highest margin & Maximum work flow as well.

Prepared a crisis plan during the recession period in 2008 to monitor the increased cost of blended products after influencing with sharp increment of base oils prices.

Established & processed a rehabilitation maintenance plan with concerned agents to fix all defected laboratory devices, evaluated two applied tenders for supplying new devices, supervised the commissioning & operation phases, managed a trade-in contract to replace a defected ICP device with a new one after many unsuccessful trials for repairing.

Established a protective maintenance & calibration plan and followed-up its implementation with concerned suppliers as per the schedule.

Issued an inventory log to track all stocks of laboratory chemicals versus their minimum stock which was calculated based on the average monthly consumption of each item, monitored laboratory

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operational cost to be within budgeted limits by comparing average purchase value versus purchased units.

Supervised the analysis process of used oil samples and recommended requested actions to be considered whither changing the oil or re-sampling after certain working hours.

Issued laboratory tasks analysis and helped in the identification of critical tasks, trained laboratory team on associated corrective & preventive actions.

Worked on raising the safety awareness among laboratory team, stimulating them to present more near-misses and discussing in details how to improve the quality of presented reports.

Main Achievements No customer complaints were received within laboratory domain. Launching the QC plan (reference of analysis). Increasing the number of valid formulations from 15 formulations to 170 ones. Margin increase by 80% before recession as well as adjusting product sales mix ratio from 90% main

product to 65%, accordingly (balance of the mix). Maintaining the negative margin from 600 EGP/ Ton to average 100 EGP/ Ton by introducing new

special formulations (during the recession period in 2008). Operating laboratory devices smoothly and increasing the capability to cover all essential analysis by

purchasing new devices & hiring 4 personnel in one year after extending the scope of analysis. Analyzing & reporting 300 used oil samples. Raising the technical level of subordinates through continual review of technical issues. Implementation of CAPA associated with identified critical tasks as well as reporting near-misses that

needed immediate actions.

MISR Petroleum Company (June 2004 till June 2005).Position: Laboratory chemist in lubes plant.

Learnt the basic analytical skills for lubricants analysis as well as their raw materials constituents.

Laboratory Analytical Skills

I have the ability to analyze the kinematic viscosity, flash point, pour point, foaming tendency, total base number, total acid number, water by distillation, fuel diluents by distillation, and metals by ICP metal analyzer, compositions of used oil by FTIR, penetration & dropping points of greases.

Training Courses

Lead auditor ISO 9001 2008 (by ERICA organization, in 2012). Awareness ISO 9001 2015 (by TUV Rheinland, 2014). Lead auditor OH&S 18001 (by ERICA organization, in 2013).

Computer Skills

Proficient knowledge of MS office (by Arab academy for sciences & maritime transport). Excellent internet research skills.

Linguistic Skills

Fluent in spoken & writing English.

Extracurricular Activities

Read in political, economical, historic & medical fields (I participated in general knowledge competitions during higher education at Alexandria University).

Play Chess since 1998.

References

All references are available upon your request.

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