Talaat A.

Kader
talaatakader@yahoo.com
01145588800

Total Quality Manager

Manufacturing quality planning Strategic Planning Operational Quality
TQM chemical industries plastic oil/ gas

Extensive background in implementation and managing integrated management system (IMS) according to ISO
9001:2015, ISO 14001:2015 and OHSAS 18001:2008.Professional experience in quality problem solving, and compliance
issues by using all quality tools as FMEA, SPC, PPQA,MSA, Fishbone analysis, 5S, internal audits, in manufacturing
chemical, cement, Calcium Carbonate, and plastic compounds and metallic industries. Six Sigma and Lean
manufacturing champion and proven experience in Six Sigma methodologies for ensuring top Quality with zero defects.
Key strengths represented in organization, problem solving, accuracy, attention to detail and guiding, influencing and
educating teams to achieve compliance goals. Set and established the quality policies, objectives, quality planning, quality
budget, quality KPIs and strategies and communication with national and international certifications organizations. Lead
the company in external corporate audits and quality meetings in USA, Spain, Mexico, and Dubai.
CORE COMPETENCIES
Project managemet Startup skills ISO 9001, 14001:2015
Process improvement Risk Management OHSAS 1800, FMEA,
Product improvement Strategic planning 5WHYS, 5S
Lean &six sigma system Suppliers Contract Review Metrology& calibration
 NDT inspection Supplier management Manufacturing/service

PROFESSIONAL EXPERIENCE
Carbon -TSI Egypt 1/1/2017 --- Now
Quality Manager
The scope of the company is providing technical expertise and training in the field of quality management
system, EHS management system, project management system in Egypt and Middle East and certified in
safety and environmental inspection. I have the following achievements:
1. I have implemented integrated quality and EHS management system in major chemical and
petrochemical companies and oil service companies in Egypt and Middle East according to ISO
9001:2015, ISO 14001:2015, OHSAS 18001:2007, ISO 29001 and shifting to ISO 45000 API Q1ad
APIQ2
2. Skillful in correcting the process nonconformity and proposing and controlling CA, CPA to improve
the quality and reduce the costs represented in scraps, reworks and off specs.
3. Certified in Non Destructive test NDT by using x-ray and radioisotopes of all kinds in oil fields and
scientific research organizations
4. Certified as lead auditor by IRCA in ISO 9001:2015, ISO 14001:2015, TS 116949 and risk assessment.
5. Established QMS in several automotive feeding industries as glasses and plastic compounds.
6. Provided lot of services in metrology and calibration and measurement in several industries.
7. Certified quality manager/certified quality auditor by the European organization of Quality.
8. ISO 9001:2015,ISO 14001:2015 and OHSAS 18001 lead auditor by IRCA

Lufkin Middle East (GE oil &Gas) 12/2007 – 12/2016

Lufkin Middle East is a branch from Lufkin Industries, Houston, Texas. The scope of this branch is sales and distribution
of artificial lift equipment, installation and servicing in oil fields in Egypt and Oman. I have received formal training in
Lufkin pumping school, Houston, Texas. USA.
Quality/EHS Manager
I have transferred the company from sales office in Egypt into prominent Business and service center and qualified the
company for integration with GE oil and gas. I had taken the initiative of launching strategic process analysis which
resulted in comprehensive business process improvement. Continued customer contact and site tours to enhance
customer retention and customer satisfaction. I have taken the following responsibilities:

1. Led the management team in setting the overall quality objectives and targets and the Quality policy, and the
quality plan of the company.
2. Held responsibility implementing of quality policies, procedures, processes, programs, and practices to ensure
Lufkin and its contractor’s continuous conformance with appropriate standards and regulations of the company.
3. Planned the internal audit program and I have trained and qualified the team of internal auditors.
4. Lead the process of internal audit according to ISO 19011 and proposed and audit the non-conformity and
CPA, CA
5. I have the responsibility of auditing and qualifying all suppliers and I have to set the suppliers approved list.
6. Designed, reviewed and implemented formal tender and contract management system to improve proposal win
rate from base line 20 % to target 80%. Directly coordinated with the contract team to maximize efficiency and
performance to ensure the contract remains in gain share.
7. Interfaced & coordinated with owner companies and consultants for preparation of bid documents, review of
bid documents, agreements, preparation of various reports for internal and external management.
8. Continual monitoring and reporting on all contract specific key performance indicators including service
output, client satisfaction, cash forecasting and staff training.
9. I was mainly responsible for coordination, monitoring and review of various activities and Controls during
stages of Pre Contracts and Post Contracts; and periodical review of activities relating to Quality, Safety,
Security and Environmental Protection.
10. Provided Quality Control Check List for each definable feature of work and implemented them into the daily
oilfield services and shipping yard activities by the QC representatives and also by subcontractors;
11. Established internal audit plan according to the standard to find out the non-conforming NC, recommended
corrective action plan and registered on action tracking system and follow up I management review meeting.
12. Technical assistance to customers as needed supported trade shows, maintenance seminars and conferences
throughout Egypt, Oman, Dubai and USA.
13. Representing the company in technical and quality conferences and annual meeting in the United States and
14. I have led the team of operations and engineering in the application of the safety design of the product which
represented high competitive advantage in addition to regulations compliance.
15. Oversaw product specifications, supplier requirements, testing, inspections, part verification, equipment
procurement and calibration; corrective actions, non-conformances, benchmarking, and voice of the customer.
Key Achievements:
1. I have implemented Lufkin Middle East and GE oil and gas integrated QEHS management system according to
ISO 9001:2008, 2015, ISO 14001:2004, 20015, ISO 29001, and OHSAS 18001:2008 which constitute
competitive advantage in oil service companies.
2. I have implemented, and certified API Q1 for the company for the first time for Service Company.
3. I have implemented the company Quality manual and process picture mapping manual and communicated to
field team as the Lufkin documented procedures for compliance and improvement.
Egyptian Polypropylene Woven bags co. 11/2005 – 12/2007
Plant Manager
My main roles and responsibilities were to re-organization and re- operation of the company after shutdown due to
technical and managerial problems. Developed short and long-term sales strategy, and partnered with executive personnel
to align strategies with corporate goals.
Key Achievements:
1. Reviewed all the raw materials suppliers which included PP, PE, master batch and additives which produce high
quality excellence that meet customer requirements and exceed customer expectations and minimize the waste
and recycles.
2. Maintenance of the extruders and cooling utilities and the water system which feeds the chillers and cooling
towers to overcome the problem of thickness variation which was the root cause of waste and losses that lead to
factory shutdown. This step saved LE.5000000 /month.
3. I have initiated lean management principles to reduce waste and improve quality. Immediately identified LE
1000.000 saving from extruder, spinning and slitting operation in addition to saving of indirect costs while
simultaneously broadening capabilities.
4. I have performed comprehensive market analysis and market survey for identification of new target market for
cement Polypropylene bags in Egypt and Middle East.
5. I have lead the R&D and production team in the process of new product design using the same production line,
planning, production and verification and validation of the product in the market.
6. I have launched maintenance plan of the spinning lines as the major line in production, and eliminated the
problem of spare parts and Setting performance indicators (KPI’s) to control all processes.
7. Due to the application of the above mentioned technical improvement and marketing and sales strategies we
have achieved higher margins and higher ROI by applying the following operational tactics and procedures:-
 Retraining of the production and quality employees.
Alcoa CSI- Egypt 4/2003 – 11/2005
Alcoa CSI Egypt is a branch of the American multinational Alcoa. The company specialized in the manufacturing of
polypropylene and polyethylene closures for beverage and water by using compression molding techniques. I have
worked in cross functional team to establish the company in Egypt and participated in all startup processes that
included plant layout, construction, material procurement, machine commissioning, machine installation, operations,
developing and implementation of standard operating procedures for production, operation, and quality and product
design. I have received formal training on Alcoa business management from USA, Mexico, Spain and Bahrain.

Quality/ EHS /Process Manager

Selected for the business startup and participated in the project construction management. The $10 million project
involved demolition, excavation, underground work, Dredging, Construction, of 3 Polypropylene closure production
plants, 4 raw material storage tanks of capacity 200 tons , loading bays, warehouses, Open storages, Bulk Conveyor
System, headquarter buildings, Electrification, Instrumentation, Roads, drainage, Water and other Utilities. Oversaw all
phases of project execution; approved engineering/design changes, troubleshot and resolved complex technical
problems, consistently meeting project deadlines and highest possible quality standards
Key Achievements:
1. Construction project quality management I have been the key person during the construction phase and
reported directly to project manager in USA. Held responsible for construction quality system.
2. Led the development and execution of engineering, procurement and construction (EPC) of process plant
projects in plastic and petrochemical industry.
3. The project construction phase ended with only one month lag and with compliance to all regulations and
without any safety or environmental accidents. Incident rate was Zero
4. Process and quality engineering :Responsible for Process Engineering, Product Quality, Quality Systems &
Continuous Improvement strategy development & deployment for 3 manufacturing locations.
5. LEAN system :Set up system to utilize ERP software to track spare parts for equipment and molds, which led
to the optimization of critical spare parts inventory and the minimization of commercially readily available
items to reduce maintenance-related inventory levels by 10%.
6. Utilized lean/six sigma concepts, such as process mapping, DMAIC project methodology, statistical tools and
root cause analysis to streamline operations in several areas, including the simplification of inspection
processes to reduce redundancy, which resulted in a 27% reduction in labor.
7. I have set the raw materials specs that comprise PP, PE, PVC, Additives, inks and solvents and performed all testing
to select the best vendors. I have successfully qualified local suppliers for Polypropylene which saved 20% of raw
materials costs.
8. I had the responsibility of designing and formulation of new products and validated with our major multinational
customers.
9. I have solved lot tons of technical problems within customer’s factories especially in bottling process.
10. Achieved market share of 95% of the Egyptian market directly after start-up due to high quality of product
and customer support.
11. I have established standardized process set ups allowing production processes to be more consistent and
proceduralized the operations to be acceptable by customers during customer audit.
12. I have implemented QEHS management system, GMP and industrial hygiene system to meet FDA specs and
customer requirements as food contact packaging.
13. Application of lean /six sigma tools such as process mapping, statistical analysis and root cause analysis that
resulted in the following:
14. Scrap rate reduction
15. Production efficiency Increased to 95%of the standard.

Technopack. 7/1995 - 3/2003

Technopack is the largest Middle East Company in the manufacturing of Biaxially Oriented Polypropylene film BOPP
and Metalized polypropylene film in addition to Cast Polyethylene and cast polypropylene films for packaging of food,
detergents, cigarettes and pharmaceuticals. Participate in the $5 million project of new factory expansion
Quality/RD Manager
I had been recruited to be change agent to improve the quality of products and the quality of processes and to overcome
the high percentage of scrap, defected materials and the high percentage of rejected products by all customers. The
company was in a situation of severe losses and I had been recruited to restore the company to profitability and know
how improvement. I have managed raw materials formulation and raw materials research to be compatible with the
situation of the production lines.
Key Achievements:
1. I have established long term and short term research on both BOPP line and cast line to study the problems of
plastic deformation due to stretching beyond the elastic limit, corona treatment decay due to additives
migration, thickness variation, film brittleness, that resulted in problems in printing registration and during
lamination.
 2. I have introduced considerable improvement in the performance of the extrusion process, chill roll
temperature and stretching temperature and changed the stretching ratio and changed the film formulation and
design which constituted very considerable technical improvement.
3. I have performed the research also in coordination with customer and through excessive customer factories
visit and inspection of films and raw materials during film processing.
4. I have reduced the additives ratios especially slips agents and antistatic to reduce migration and keep the film
wettability for long time. I have saved 95% of the additives every day which saved more than LE 200000
every day.
5. I have reduced the percentage of scrap to be the minimum according to 2 sigma process and taking the scrap
to efficient recycling process and added to the product and simultaneously keeping the high quality and the
standard specs of the film.
6. I have reduced the rejected materials to zero and enhanced customer satisfaction due to the improvements that
mentioned above.
7. I have improved the performance of the cast line and economically operated it after standstill and designed
new products to meet new customer’s requirements.
8. I have introduced and qualified new raw materials suppliers to work with Technopack to guarantee the
continuous production flow. I have qualified Sabic, OPC, Solvay; Schulman, and other companies.
9. Due to the above mentioned improvements and due to new products design, the market share has been
elevated to more than 90% of the Middle East market.
10. The company has tripled the production capacity by expansion and adding new BOPP lines of 40 ton/day to
raise the production capacity from 20 ton/day to 60 ton /day of BOPP film in addition to cast film of 10
tons/day.
11. I started the company with 20 tons production capacity with efficiency less than 60%, 20 % rejected and off
specs, and ended with capacity of 70 tons of efficiency 96%
12. I have introduced high-impact staff improvement initiatives that increased performance and morale through
proper training, dedicated leadership, and unwavering employee support.
13. I have been selected to be the management representative to certify the company to ISO 9000 and Technopack
was the first to be certified in Egypt.

AMC SPREA - Misr 4/1993 – 7/1995

AMC Sprea is Italian company for the production of thermosetting plastic products, melamine molding compounds,
urea molding compounds and phenol molding compounds. I have established Quality department from scratch. Set the
specs of raw materials and final products and supervision on all reaction processes. I was responsible for the
formulation and setting the process conditions of all products.

Lab/ RD project manager

Recruited to establish the chemical and physical and RD laboratory from scratch. I started as the project manager for
the construction and instrumentation of $2 million quality control and research laboratory. Coordinated efforts with
production and material managers to produce for quality and design new products to expand market share and
increase profits for the Egyptian branch of AMC Sprea. I have participated also in quality control of the
Formaldehyde factory construction that included main building construction, factory disassembly, assembly,
electrical work, utilities, and pre-commissioning, commissioning, water treatment plants for feeding the factory,
storage tanks, and underground storage.
Key Achievements:
1. Established all quality documentation and all required documentation by customer, regulatory organizations
and corporate.
2. Project construction management: management of the company’s Quality Control Program and development
and implementation of the Quality Control Plan including the three phases of control, testing, commissioning
and final acceptance of the laboratory.
3. Oversaw construction stages for compliance to project drawings and specifications.
4. Review work schedules and implement corrective measures to comply with project schedule
5. Established RD laboratories that included physical, chemical and water treatment laboratories.
6. I have set the specs of all raw materials, the main raw materials, catalyst, additives and fillers.
7. I have direct supervision on the operations quality of boilers, water treatment plants and demineralized water that
feed the Formaldehyde plant.
8. I have replaced the Italian factory manager in formulation and set the bill of material for products and set the
operations parameters for reactors.
9. I have put the specs for all materials required and participated for establishing the approved supplier list. I have
succeeded to procure the main raw materials from the local markets especially Formaldehyde, Urea, barium
sulphate, calcium carbonate, etc. after series of researches with the Italian mother company, Egyptian local
companies.
10. It is me who established the Egyptian Standards of urea formaldehyde, Melamine Formaldehyde, and Phenol
Formaldehyde in the presence of representatives from Cairo University, Egyptian organization of
 Standardizations and representative of the major thermosetting plastic. The standards had been approved and
applied by the Ministry Of industry in Egypt.

EDUCATION
1. Bachelor of Science in chemistry (BSC.): Ain Shams University – Faculty of Science.
Concentration in industrial chemistry and organic, non-organic and physical chemistry. Minor
in Business, math. and Physics
2. Higher studies Diploma in Total Quality Management: American University in Cairo,
concentration on designing for top quality and achieving customer satisfaction and statistical
process control
3. Higher studies diploma in Business Administration: Ain Shams university, Faculty of
commerce, 2-year diploma that covered corporate finance, strategic management, operations
management and negotiation skills and management theory
4. Higher studies diploma in Managerial economics: Al-Azhar university : 2 years
5. Higher studies diploma in human resources planning and development: Al-Azhar
University, 2 years which concentrate on Strategic management, human resources management,
strategic planning, theory of management,
6. Master of Business Administration: Cairo University, faculty of commerce. I have finished the
program in 3 years that covered the following courses:
 Marketing management Strategic management
 Organizational behavior International business
 Operations management Managerial accounting
 Managerial finance Human resources management
 Research methodologies Quality management and six sigma
 Leadership and negotiation Information technology

7. NEBOSH international diploma 2014

8. Nebosh international general certificate 2009 with distinction
9. Sucker Rod Pumps installation, and maintenance from the Pumping school in USA.
10. IOSH managing safety in 2012

TECHNICAL PROFICIENCIES
1. Microsoft Office (Word, Excel, PowerPoint and Visio)
2. Photo Shop, Integrated ERP Software

Languages
1. Arabic, mother language
2. English, excellent
3. French excellent
4. German very good