Atef Garsaa

Engineering | Production | Operations Automotive

Salaire / Taux journalier

91590 Mondeville, France

Freelance

Peut venir sur site

Expertises

Site reliability engineeringKnowledge ManagementStratégie ProduitProduct ManagementProject Owner

Langues

Arabe (Maternelle)Anglais (Courant)Français (Courant)Allemand

À propos

Introduction

Engineering Director with 18+ years of automotive industry expertise in production management and operations optimization. Led cross-functional teams at global companies like DRÄXLMAIER, Bosch, and Amphenol, delivering strategic improvements in manufacturing processes. Specialized in performance evaluation, strategic planning, and operational excellence to drive measurable results for automotive clients.

Liens

Expérience de travail

Central Engineering Director -Automotive Industry

Coroplast Group

déc. 2024 - Présent

1 an 11 mois

Soliman, Tunisie

Mission: Provide visionary leadership across all engineering functions for 02 automotive wiring plants in Tunisia. Drive the successful execution of new product launches and relocation projects, while overseeing the global plant layouts that elevate operational benchmarks, enhance performance competitiveness, and support long-term strategic growth.. Main tasks:  Leadership and Team Development : - - Leading and coaching to a team of 28 industrial and process engineers, fostering a culture of ownership, and continuous improvement through KPI-driven performance tracking. Create and implemente a framework for continuous individual competency evaluation, integrating focused training plans and structured career path development. This initiative led to a 32% increase in team technical polyvalence reinforcing operational excellence and cross functional resilience.  Program Management and Process Industrialization: - - - - - Lead industrialization of 09 New major harness projects for OEMs including WV, Audi, Ford, JLR, Mercedes, Tesla, BMW, achieving sucessufelly all project phases till SOP within planned timelines and zero launch delays. Continous delivering successful relocation of 16 serial projects (128 variants) from Poland to Tunisia, saving costs by 22% and improving lead time by 18%. Ensured readiness and formal approval of all production process layouts and documentation, guaranteeing full compliance with customer requirements and internal standards. Oversaw Ramp-up phases reaching target takt times within 4 to 6 weeks, ensuring stable production based on customers requirments and internal efficiency and scrap rate targets. Conduct, implementing and tracking of product and process Change request with prototypes,  Continuous Improvement and Layout Optimization for global serial projects : - - Conducted 4 lean manufacturing workshops, optimizing layout flow and reducing internal material handling time by 35%, 87% balacing of process steps, 12% increase in production process efficiency, 7% reduction in scrap rate across key harness and 8% boost in FPY. Development and design of new E2E layout extension for the 2nd plant part.  Financial and Operational Management : - - - Managed annual budgets exceeding 2.1 Mio€, with real-time cost tracking. Delivered 11% cost savings through process automation, and resources reallocation. Achievement of 65 K€ ROI through Continuous Process improvements roadmap,  Quality and Safety Compliance : - - - Achieved full compliance in internal and customer audits, throught VDA 6.3 standards. Conduct of offical external IATF 16949 audit for Engineering Department without deviation, Reduced safety incidents by 19% year-over-year via enhanced safety technologies, LOTO procedures, safe and ergonomic workstations.

Production Director- Automotive Industry

DRÄXLMAIER Group

sept. 2020 - oct. 2024

4 ans 2 mois

Tunisie

Mission: Implementing and Startup Production for New Plant -Green Field of first 100 % Electrical KSK for eQ6 Audi project in Draexlmaier Tunisia . Main tasks: - Oversee the daily operations of production and develop strategies to meet production goals while reducing costs to ensure plant profitability and sustainability, - Set Layout and Implementing new whole Production equipment’s in the new Plant (Greenfield), - Set and followup investments and charges Budgets, - Define and implement production phases with KPI’s target, - Define collaborators needs, Training and Performance development of employees -1250 employees, - Achieved 91% score in VDA 6.3 process audit and R@R, with zero major findings across P2–P7 elements and ensuring full SOP approval. - Developed workforce training and performance systems, achieving targets line efficiency by 63% and reduced scrap rate by 14% within the first 100 days post-launch - Driving kickoff SOP through smoothly planned Production Rampup, - Ensure that all products and processes meet the standards of quality and compliance. - Plan, organize, drive and run optimum day-to-day production to exceed our customers’ expectations in terms of Quality, Quantity and in Time delivery, - Delivery solutions, maximising performance, productivity and profitability against pre-agreed targets, - Drive and reporting KPI’s with consistents PDCA, - Lead and set overall maintenance department activities and goals, - Developed a data-driven maintenance strategy that reduced downtime and increase availability , - Ensures all health, safety, and regulations are followed according to procedures, - Benchmarks Development opportunities for new projects acquisitions :New BMW eCar project 2024 - Employee Orientation : implementation Employees Proximity Concept engagement with regular follow-up and Organize regular ceremonies for employees motivation : best employee, best idea, - Ensure successful internal, Customer and certification audits.

Operations Manager

SAH Lilas

janv. 2015 - août 2020

5 ans 8 mois

Tunisie

Mission : Management and optimization of production’s processes and means in compliance with regulatory and customer requirements in terms of quality, time, cost and security. Main tasks : - Implement Strategies and Visions for mid and long Terms, - Set and managing budgets, forecasting, and allocating resources to meet business and strategic goals, - Developing and implementing operational policies and procedures to ensure efficient and effective operations, - Ensuring that organizational processes remain legally compliant with regulations and standards, - Monitoring the performance and productivity of employees and teams, providing coaching, training, and feedback to improve performance, 3 4 - Working cross-departmentally with a wide range of stakeholders to ensure that all operations are aligned with organizational objectives, - Developing and establishing business relationship and contracts with customers and suppliers, - Performing quality assurance controls to ensure the company’s products and services meet customer expectations and monitoring production KPIs and metrics, - Reporting KPI’s with relevant PDCA to Steering Committee, - Maintaining and enforcing health and safety guidelines.

Maintenance Manager

Danone Group

nov. 2013 - déc. 2014

1 an 2 mois

Soliman, Tunisie

Mission: Implement a strategy of corrective and preventive maintenance to ensure a high performance of equipment’s for production activities. Main tasks: - Implementation of the maintenance plan • Control the budget dedicated to the maintenance, • Identify maintenance cost optimization axes, • Organize and improve the production equipment maintenance, • Define the human, financial and technical resources. - Supervise of the maintenance activities • Manage the maintenance team of 53 supervisors and technicians • Follow the synthesis of curative and preventive reports • Manage the means and resources for maintenance (distribute assignments technicians and equipment ...). • Establish and monitor indicators of service activity (KPI’s, reporting ...). • Follow the realization of investments and Charges in relation to the budget. - Maintenance of production equipment’s • Ensure the availability of equipment and meet the objectives of service productivity management (iterative failures, improving the technical offer ...). • Ensure corrective maintenance of equipment’s (workshop repair, emergency plan ...). • Implement preventive maintenance programs (control, corrective actions, predictive maintenance, process TPM-Total Productive Maintenance ...). • Manage and monitor contracts to subcontractors. - Implementation of regulatory controls • Prevent and manage environmental impacts and safety. • Application of LOTO (Lockout/ Tagout). • Assess and monitor the training plan teams in terms of quality and safety interventions.

Engineering and Project Manager -Automotive Industry

Amphenol-Tuchel Electronics

août 2009 - oct. 2013

4 ans 3 mois

Soliman, Tunisie

Mission : Providing the lead, oversight and coordination of Projects launches, from cradle to grave including engineering changes in adhesion with Overall Plant Vision and Goals . Main tasks : - - - - - - - - - - - - - - - - - - - - - - - - - - Department Lead: 06 project leaders, 02 Change Management leaders and 02 technical and tools coordinators, Management of maintenance service which contain 18 persons, SMART Goals setting, plan Budget and follow-up expenses, Led new product launches for major OEMs, compliance cost, quality, achieving 98% of projects in Time delivery Directed project transfers from Germany, Czech Republic, USA, and Mexico, coordinating full lifecycle from Kick-off to SOP with average 94 % customer audits results. Driving projects from inception through to production, ensuring that all aspects of the project align with the defined goals and Customer’s requirements, Lead the APQP process for new product launches, ensuring that all specifications are met in terms of Customer’s expectations, cost, quality, and in time delivery, Oversight and Coordinate with all stakeholders to deliver the project according to agreed targets within high level of excellence, Lead and actively participate in continuous improvement by employing best practices for operational and product performance with optimized cost. Implements quick, effective solutions to enhance production efficiency without out budget costs, Communication and sharing weekly KPI’s reporting of projects progress and Maintenance activities with effective PDCA, Layout management: optimise space, process flow, installations, buildings ... Coordination of all transferred and new projects within plant(s) from Kick off till SOP New products project calculation based on customer RFQ Convert and create of products in SAP « System Application Product » Definition of varieties, operating procedures, needs assembly means and tools… Establishing a balance between increased productivity and reduced costs of production process throughout product lifetime, Oversight Product and process Change Management, Lead, coaching and mentor Change Management, fostering implication and collaboration stakeholders, Identifying, analyzing, and evaluating potential risks associated to the required changes, Mutual coordination and commitment for customers potential changes. Calculating the ROI -return on investment- and expected changes benefits Define and application of overall working procedures and instructions, Ensuring all safety and health standards are met, Implementation of CIP « Continuous Improvement Process » Drive Lean Line Design workshops management- Lean Manufacturing :VSM VSD, Plant P- FMEA management.

Industrial Project Leader- -Automotive Industry

Bosch Group

janv. 2006 - juil. 2009

3 ans 7 mois

Soliman, Tunisie

Realised Project from building prototype until SOP: • Managed end-to-end delivery of OEM projects, • Reached OEE above 90%, Main Responsibilities : - Manage project schedules and communicate with stakeholders the progress through reports, presentations, etc. - Specify and assign the necessary resources for each project based on the existing structure, - Orchestrate activities to lead the Team efficiently to achieve project objectives, - Production Process planning and preparation for new products, - Lead Process and/or products transfers between plants, - Calculation VT, Capacity, Tact Time and workplaces balancing, - Define Direct Labor needs according for each Production areas, - Set Ramp-up curves according to customer’s forecast, - Drive Workshops: Lean Line Design (Lean Manufacturing) according to BPS _Bosch Production System, - Continuous Improvement of production and quality KPIs: OEE, FOR, productivity... - Ensure Standardized work in production lines, - DFMA : Lead Design For Manufacturing and Assembly , - Coordinator and Moderator of P-FMEA, - Coordinator of Statistical Process Control (SPC), - Co- auditor according to ISO/TS 16949:2002.


Formation

Engineers’ National School of Tunis (ENIT)

Mechanical Engineering Degree, Engineering

1999 - 2004

4 ans 10 mois

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