Ayman Abu Zaid

Launched potato chips plant and built operations from scratch, leading production, engineering, quality, and PepsiCo co-manufacturing integration. Key Achievements: ● Reduced YTD25 Material Usage Variance (MUV) compared to FY24 by 35% by: reducing raw and packaging material consumption rates : - potatoes yield by 11% - oil consumption by 14% - Flavor consumption by 6% - packaging material consumption by 4% resulting in accumulative cost saving of $1.2M. ● Ramped up the plant OEE from zero to 50% over 20 weeks period in 2024 (March to August ) by focusing on : - elimination of the highest contributing sources of technical downtime in the process line. - speed loss in the packaging area. - reducing change over time by 25% by rearranging changeover activities, providing adequate tools, implementing engineering solutions that helps with cleaning activities and training front liners. - working on improving FTR%, reaching YTD25 78% from a baseline of 60% FY24 ● Improving total plant OEE by 13% from 48% FY24 to 61% YTD 25

Led P&L and operations of two mega-scale water treatment plants (20M+ m³ annual capacity) serving industrial cities and 300K+ population. Key Achievements: Reduced energy consumption per cubic meter by 12% via pump efficiency projects and night-load optimization. Implemented downtime root cause tracking, cutting unplanned outages by 25%. Led end-to-end AOP planning and achieved budget variance below 3% for key customers for FY23.

Oversaw full operations (production, engineering, quality, and supply chain) for HDPE/PET blow molding and injection molding plant serving Unilever, Henkel, and P&G. Key Achievements: Improved OEE from 62% to 78% in Q3 2021 by: - reducing EBM "extrusion blow moulding machines by cycle time by 12% - launching daily Gemba walks. - reducing color change time by 25%, by rearranging the colors sequence in the production plan and introducing process aid material. Increased resin yield, reducing COGS by $130K in Q3 2021. increased OTIF from 86% to 92% by redesigning order-to-delivery scheduling and logistics handoff process.

Managed the two largest French fries manufacturing facilities in the Middle East, overseeing operations to ensure optimal production and efficiency. Key Achievements: •Implemented initiatives that led to an $450K reduction in cost of goods sold (COGS) in FY 2020 by increasing potato yield by 1.5% and reducing oil consumption by 8% versus budget. •Reduced packaging material cost by $185K by optimizing poly thickness and carton dimensions. • Acted as engineering lead in the Egyptian team for $40M greenfield plant project—oversaw design, vendor selection, FAT, installation, and startup in partnership with Farm Frites international global project team.

Key Achievements: • Reduced technical downtime by 40% YoY through focused maintenance KPIs, spare parts stock optimization, translating to operational cost reduction of $152K • Delivered 3 major overhauls on time and budget ($600K each). • led execution of water saving projects in 2016, resulting in a cost-saving of $100K by reducing water usage by 30%. • Re-engineered ammonia system on IQF tunnel, boosting capacity by 33%.

Led the operation of returnable bottles and cans beverage filling lines, overseeing critical processes to ensure optimal performance and efficiency. Responsibilities: • Process Control Enhancement: Analyzed process control outcomes and implemented adjustments to enhance the performance of the filling lines, contributing to improved operational outcomes. • Production Objective Management: Developed and executed strategies for structuring and managing plant production objectives, aligning efforts with organizational goals. • Policy Compliance Oversight: Ensured meticulous compliance with plant policies and procedures, guaranteeing adherence to quality standards and operational regulations. • Collaborative Technical Support: Collaborated closely with senior management to provide technical support, aiding in resolving complex operational challenges and fostering cross-functional collaboration. Key Achievements: • Strategic Productivity Enhancement: Strategically reduced production headcount by 18%, optimizing labor productivity and resource allocation. • Operational Efficiency: Elevated the efficiency of the Returnable Bottles (RB) line by an impressive 15%, earning recognition as the #2 ranked team globally within PepsiCo. • Top Performer Recognition: Received the prestigious 2015 Chairman's Circle of Excellence Award, celebrating exceptional achievements and contributions as a top-performing global professional.

Guided the development of comprehensive sustainability action plans, propelling productivity strategies while fostering environmental consciousness throughout plant operations. Collaborated closely with Plant Manager to outline Annual Operating Plan (AOP) KPIs, ensuring alignment with organizational objectives and performance targets. Revamped and refreshed business continuity plans in close collaboration with stakeholders and staff, enhancing preparedness and resilience. Championed the formulation of investment programs aimed at reducing energy consumption, minimizing wastage, and lessening environmental footprint. Identified and capitalized on funding opportunities to support sustainability initiatives, enabling the organization to make meaningful progress toward environmental goals. Pioneered the integration of a KPI tracking system and analysis tools, enhancing transparency and enabling data-driven decision-making. Key Achievements: • Operational Safety Enhancement: Simplified the global Health & Safety Handbook to cater to blue-collar employees, ensuring clarity and accessibility of safety guidelines. • Continuous Improvement: Utilized the Kaizen strategy to foster a culture of continuous improvement and collaboration across all organizational levels. • Resource Efficiency: Successfully executed a project resulting in a remarkable 30% reduction in bottle washer consumption, from 31 m3/hr to 21.8 m3/hr, contributing to both cost savings and sustainability goals. • Process Optimization: Coordinated the implementation of a project on Returnable Bottles (RB) lines, increasing product loadability by an impressive 20% through improvements in palletizing layer patterns.

Oversaw the comprehensive overhaul and maintenance of vital central utilities, including air compressors, ammonia compressors, steam boilers, chillers, syrup preparation plants, ultrafiltration, RO treatment, and wastewater treatment systems. Formulated and managed annual budgets, meticulously maintaining monthly costs within target thresholds to ensure optimal financial performance. Championed the implementation of standardized preventative maintenance programs, driving enhanced machinery performance and operational efficiency. Compiled detailed monthly reports encompassing future plans, consumption monitoring, and achieved cost savings, providing valuable insights for decision-making. Strategically managed equipment inventory processes, overseeing the planning and ordering of spare parts to ensure seamless maintenance operations. Key Achievements: • Operational Enhancement: Successfully eliminated refrigeration downtime by refining the design of the RB line ammonia refrigeration system, optimizing production continuity and minimizing disruptions. • Critical System Enhancement: Identified and addressed a design flaw in the ammonia refrigeration system, which had been impeding the mega PET production line by blocking up to 33% of its capacity. my intervention undoubtedly enhanced production efficiency and capacity utilization.