Helmy Ahmed

Production planning engineer

Key Highlights: • Production Planning & Operations: • Developed and executed detailed production plans aligned with demand forecasts, capacity, and raw material availability. • Supervised end-to-end cosmetics manufacturing operations — mixing, filling, and packaging — ensuring on-time delivery, product quality, and safety compliance. • Achieved OEE improvement of 12% and 20% reduction in batch cycle time through root cause analysis and process optimization. • Coordinated with procurement and warehouse teams to ensure material readiness using SAP ERP (PP/MM) and MRP systems. • Process Optimization & Lean Manufacturing: • Implemented Lean Manufacturing tools (5S, Kaizen, SMED, Kanban) to eliminate non–value-added time, balance workloads, and enhance line efficiency • Led process improvement initiatives that reduced raw material waste by 18% and improved workflow across production lines. • Conducted RCA and CAPA exercises to address downtime and prevent recurring deviations. • Improved production layouts and equipment utilization, increasing throughput and flexibility for new SKUs. • Six Sigma & Quality Excellence: • Actively contributed to Six Sigma (DMAIC) projects targeting yield improvement, defect reduction, and product uniformity. • Maintained full compliance with GMP, ISO 22716, and internal cosmetic manufacturing standards. • Supported validation and scale-up of new product formulations from pilot to commercial batches. • Equipment & Process Control: • Monitored machine performance, process parameters, and critical control points to ensure product consistency. • Coordinated preventive maintenance schedules with the engineering team to minimize unplanned downtime. • Updated and standardized batch manufacturing records and SOPs for improved traceability and audit readiness. • SAP & Data Management: • Used SAP ERP for production order tracking, MRP execution, and real-time performance reporting. • Enhanced visibility of production KPIs (OEE, yield, cycle time) through digital dashboards and data analysis tools. • Cross-Functional Collaboration & Leadership: • Worked closely with R&D, QA/QC, Maintenance, and Warehouse to ensure smooth production flow and troubleshoot operational challenges. • Provided leadership and training for planners, technicians, and operators on Lean principles, GMP compliance, and SAP usage. • Fostered a results-driven, safety-focused culture promoting continuous improvement and operational excellence.

• Developed and executed detailed production plans aligned with demand forecasts, capacity, and raw material availability.
• Supervised end-to-end cosmetics manufacturing operations — mixing, filling, and packaging — ensuring on-time delivery, product quality, and safety compliance.
• Achieved OEE improvement of 12% and 20% reduction in batch cycle time through root cause analysis and process optimization.
• Coordinated with procurement and warehouse teams to ensure material readiness using SAP ERP (PP/MM) and MRP systems.
• Implemented Lean Manufacturing tools (5S, Kaizen, SMED, Kanban) to eliminate non–value-added time, balance workloads, and enhance line efficiency

Key Highlights: • Technical & Quality Oversight: • Led in-process quality control of cosmetic manufacturing operations, ensuring compliance with GMP, ISO 22716, and regulatory requirements. • Oversaw routine and special sampling, testing, and process checks across all production lines (creams, lotions, serums, etc.). • Implemented robust IPC protocols to ensure consistency, safety, and aesthetic quality of finished products. • Team & Process Leadership: • Supervised and trained a team of IPC technicians and analysts. • Coordinated with production, R&D, and QA teams to resolve quality issues in real-time, minimizing downtime and waste. • Documentation & Reporting: • Maintained detailed and compliant IPC records, batch documentation, and deviation reports. • Participated in internal and external audits; prepared IPC-related documents for regulatory submissions and inspections. • Process Optimization: • Analyzed IPC data to identify trends, reduce variability, and enhance product consistency. • Contributed to continuous improvement initiatives including lean manufacturing and Six Sigma practices in process control. • Product Development Support: • Provided IPC input during scale-up and validation of new cosmetic formulations. • Supported formulation adjustments and trial batches with real-time quality feedback. • Compliance & Safety: • Ensured adherence to safety and hygiene standards during manufacturing. • Conducted training on SOPs, hygiene, and compliance to uphold in-plant quality culture.

• Led in-process quality control of cosmetic manufacturing operations, ensuring compliance with GMP, ISO 22716, and regulatory requirements.
• Oversaw routine and special sampling, testing, and process checks across all production lines (creams, lotions, serums, etc.).
• Implemented robust IPC protocols to ensure consistency, safety, and aesthetic quality of finished products.
• Supervised and trained a team of IPC technicians and analysts.
• Coordinated with production, R&D, and QA teams to resolve quality issues in real-time, minimizing downtime and waste.

Key Highlights: • Formulation Execution: • Skilled in accurately executing mixing batches based on approved cosmetic formulations (creams, lotions, shampoos, etc.) while maintaining quality and consistency. • Raw Material Handling: • Strong experience in handling and verifying raw materials as per SOPs, including weighing, charging, and pre- mixing processes. • GMP Compliance: • Ensures strict adherence to Good Manufacturing Practices (GMP), Standard Operating Procedures (SOPs), and safety guidelines in all mixing operations. • Batch Documentation: • Proficient in recording batch manufacturing records (BMR), process parameters, deviations, and in-process check with attention to detail. • Equipment Operation: • Hands-on experience operating and maintaining mixing vessels, homogenizers, agitators, and vacuum systems used in cosmetic production. • Process Optimization: • Involved in process improvements to reduce mixing time, enhance product quality, and ensure batch reproducibility. • Cross-functional Coordination: • Coordinates with R&D, QA/QC, and packaging departments for smooth production flow and prompt issue resolution. • Already helped in Share with the team to get ISO certificates like”22716, 45001, 14001” and GMP certificate. • Cleaning Validation: • Experienced in CIP (Clean-In-Place) and SIP (Sanitize-In-Place) procedures, ensuring hygienic and contamination-free operations. • Inventory & Waste Control: • Monitors usage of raw materials to minimize waste and supports accurate inventory reporting. • Regulatory Awareness: • Familiar with cosmetic regulations (e.g., EU Cosmetics Regulation, FDA guidelines) ensuring compliance during production. • Onboarding & Orientation: • Conducts structured onboarding programs for new production staff, introducing them to GMP, SOPs, safety rules, and equipment operation.

• Skilled in accurately executing mixing batches based on approved cosmetic formulations (creams, lotions, shampoos, etc.) while maintaining quality and consistency.
• Strong experience in handling and verifying raw materials as per SOPs, including weighing, charging, and pre-mixing processes.
• Ensures strict adherence to Good Manufacturing Practices (GMP), Standard Operating Procedures (SOPs), and safety guidelines in all mixing operations.
• Proficient in recording batch manufacturing records (BMR), process parameters, deviations, and in-process check with attention to detail.
• Hands-on experience operating and maintaining mixing vessels, homogenizers, agitators, and vacuum systems used in cosmetic production.