Karim - Consultant Lean Six Sigma

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Photo de Karim, Consultant Lean Six Sigma
Compétences
Lean Six Sigma
Expériences professionnelles
  • Plant Director

    Nexans Autoelectric, Sousse, Tunisia (4200+ employees)
    Jan 2010 - aujourd'hui

    Automotive Wire Harness production (Tier1 for Daimler/BMW/Audi/Porsche/VW)
     Currently in charge of the launch and SOP of a new facility for BMW engine wire harnesses
    manufacturing, 7000 m², 1000 FTE’s (2021-2022)
     Successful launch of a 1100 m² production facility with 450 FTE’s (2011)
     Successfully relocated 2 production volumes from Eastern Europe to Tunisia (2011-2014)
     Strategically managed complete factory relocation from 1100 m² to 5000 m² plant including site
    construction (2014)
     Team leader in the attainment of ’Class A Manufacturing Excellence’ award (2019) (Audi)
     Team leader in the successful SOP of 1.4 hybrid engine wire harness for VW (2020)
     Awarded one of the best Caterpillar Inc. suppliers (Bronze certification) (2016)
     Successful business restructuring and change management after customer change (2017)
     Improved lead time from 26.5 to 16 days (2019-2020)
     Achieved an external delivery service level equal to 100% (2020)
     Reduced production equipment’s downtime by 34% (2019)
     Improved OEE on cutting process up to 118% (2019)
     Decreased staff turnover to 1,2%/month (2019)
     Delivered annual cost saving of 40% (2018 - Prototyping/NPI, ramp up and serial production period)
     Delivered an average customer PPM performance of 8.4/75 within a 6 sigma project (2019)
     Delivered financial benefits up to 192k€/annually, including a Benefit Cost Ratio equal to 7 within a 6
    sigma project based on internal quality performance (2019)
     Successful re-certification of IATF 16949:2016 (2019)
     Successful certification of ISO 14001:2015 (2019)
     Implemented TPM system for all existing equipment
     Directing, managing and leading a cross functional team of 7 direct reports across purchase, human
    resources, quality, manufacturing, maintenance, engineering and supply chain
     Participates in the development and preparation of short-term and long-range plans and budgets based
    upon broad organization goals and objectives
     Review and analyze activities, costs, operations and forecast data to determine progress towards
    company objectives
     Review the business processes to control business risk assessment, Health & Safety, IATF and
    Environmental
     Support the research, evaluation and recommend investments in technology, capital, equipment,
    systems or other assets that will enhance the plant’s production capabilities and material savings
     Insures adequate management of people (hiring, retaining and developing key people)
     Full accountability for site P&L
     Full accountability for KPI’s follow up and reporting to Headquarters in Germany
     Involved in union negotiation process and accountable for the social climate of the plant
     In charge of Lean Six Sigma projects

  • Plant Quality Director

    Jan 2008 - Jan 2010

    Johnson Electric, Monastir, Tunisia (200+ employees)
    Switches, actuators and control systems production (Siemens, Miele, Braun, Hella)
    Automotive Wire Harness Production (Tier1 for Volkswagen)
     Reduced customer complaints by 50% over 12 month’s period
     Successful introduction of wire harness product families for Volkswagen
     Successful re-certification of ISO9001:2008
     Delivered an average customer PPM performance of 31/200
     Implemented and monitored of the quality management system following ISO standards and customer
    specific requirements (CSR)
     Led the quality management system reviews and served as quality management representative
     Responsible for feedback to customer audits/complaints and regulatory observations
     Daily management of 20 direct reports

  • Quality Manager

    Jan 2002 - Jan 2008

    Johnson Electric, Monastir, Tunisia (200+ employees)
    Automotive & industrial switches and actuators production (Hella, Siemens, Miele, Braun)
     Achieved and maintained ISO 9001certification for over 6 years
     Conducted internal and regulatory audits (ISO9001 / UL)
     Led the process FMEAs to identify and reduce process risks
     Supported the delivery of all the internal APQP requirements of NPI projects
     Led the implementation of quality tools and techniques to drive the continuous improvement activities
    within the manufacturing processes
     Daily management of 15 direct reports

  • Logistic Manager

    Jomaa SA, Sousse, Tunisia (100+ employees) Automotive tire retail (Continental)
    Jan 2002 - Jan 2002

     Managing inbound activities related to the receipt and storage of continental tires
     Overseeing outbound activities related to order-filling and stock replenishment
     Maintains standards for cleanliness, organization, and safety throughout the warehouse
     Daily management of 3 direct reports

  • Supply Chain Manager

    Dräxlmaier Group, Sousse, Tunisia (3000+ employees)
    Jan 1999 - Jan 2001

    Automotive Wire Harness Production
     Managed demand requirements with manufacturing and supplier capacities to ensure completion of
    customer requirements
     Successful relocation of ‘Material Handling & Labelling Unit’ from Germany to Tunisia
     Implemented methods, practices and techniques to ensure the most economical movement of
    materials through the supply chain to achieve cost-effective logistics practices
     Inventory Planning/Management
     Daily management of 150 direct/indirect reports

Études et formations
  • Process management – Indice Management

    2003
  • Internal auditor DIN ISO 9001

    TÜV Rheinland, TN
    2003
  • Process audit DIN ISO 9001– Indice

    TN
    2003
  • Quality continuous improvement tools – Indice Management

    TN
    2003
  • Bachelor degree in Business Administration

    Higher Institute of Technological Studies, TN
    1996
Autres compétences
IT Tools
Microsoft Office Suite (Excel, Word, Outlook, PowerPoint)
Microsoft Project (Project Management)
SAP (ERP-basics)
Minitab (Statistics & Data Analysis)
Microsoft Power BI (Business intelligence)

Languages
English: Fluent
French: Fluent
German: Beginner
Arabic: Native
Manufacturing processes Know How
 Injection molding (Arburg)
 Wire cutting-stripping-crimping and ink jet marking on wire (Komax Alpha-Gamma-Kappa-IMS)
 MSA or machine subassembly preparation (NanoMQS) (Komax Zeta 633-656)
 Cross section analyses (Schäffer SQS02)
 Assembly on conveyor 12 stations (Pinto Brazil)
 Monitored manual terminal insertion into connector (Natur)
 Ultrasonic welding (Schunk Minic III)
 Mechanical ring splicing
 Harness/subassembly taping (Kabatec TR100)
 Twisting (Komax BT288)
 Shrinking (DSG-Canusa/TE MK4/Raychem Leister triac)
 Tin Soldering (Ersa)
 Bath soldering (Ersa)
 Braiding (Herzog/Cobra)
 Plate stamping (Suso)
 Tool and die stamping (Quickcable)
 Electrical test bench (TSK-Weetech)

Executive Highlights
 20+ years in international automotive corporates with expertise in Operations, Quality & Supply Chain
 Technology transfer, management, build and start-up of production sites (1 Greenfield + 2 Brownfield)
 2019 – Customer Award Winner (Audi) – Best Plant Quality/Ramp up
 Experienced in driving benefits through lean six sigma projects > 190k€/year
 P&L Management / Operations Restructuring / Change Management / Unionized Environment
 Working knowledge of project management including plants start-up, production relocation and NPI
 Certified IATF requirements, ISO TS/16949 & ISO/9001 internal auditor, ISO/14001 requirements
 Certified Lean Six Sigma Green Belt - TÜV Rheinland
 Certified Lean Six Sigma Black Belt - TENSTEP
 Bachelor of Business Administration
 Fluent English + Fluent French + Native Arabic + Beginner German

Executive Summary
Award-winning Leader with over 20 years of progressive growth with Automotive European companies, building and
supervising high performing multi-functional teams. Used to work in matrix organizations and international environment.
Analytical and results-oriented leader with a proven record of assessing existing operations to isolate inefficiencies,
reduce process variation, design process improvements and boost sales growth. Lean manufacturing, continuous
improvement and cost reduction expertise. Focused on KPI´s and data driven. Taking analytical perspective to make
strategic decisions. Encouraging excellence and driving accountability to deliver results. Right-First-Time mentality and
leading by example

Areas of Expertise
 Plant General Management (>700 fte’s)
 Operations Management
 P&L Management
 Capex & Opex Management
 Greenfield & Brownfield Projects
 Business & production lines transfer from abroad
 Operations Restructuring
 Business Change Management
 Business Intelligence Based Reporting
 Statistics based forecasting
 Cross-Functional Teams Management
 New Products Introduction (NPI)
 Quality Management System Implementation
 Process & System Audit
 TPM implementation
 Working knowledge of data analysis and
performance/operation metrics
 Working knowledge of quality analysis tools
including FMEA, VSM, DOE and process capability
analysis

Personal Skills
Leadership
Leader with sharp business acumen and the ability to
manage and supervise multidisciplinary teams. Leads by
example
 Strategic Thinking
Capability to determine new ways of working that
improves the business, save money and increase
efficiency.
 Decision making & Sound Judgment
Ability to react within stressful and complex situations
and easily adapt to a constant changing environment
 Communication
Ability to effectively communicate with all employees
across the organization with focus on empathy. Active
listener using interpersonal skills to resolve issues, build
consensus with stakeholders, and negotiate and mediate
conflicts
 Problem solving
Hands-on experience in the implementation and usage
of statistical tools including six sigma to define issues, to
measure the impact, to analyze the root causes, to
improve and to assess the output. Proactive way of
thinking
 Delegation
Working experience in assigning responsibilities
effectively which ensures that all functions are performed
on time and with close attention to detail

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