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Consultant, University Lecturer, Operational Excellence Leader & Author - Lean Turnaround, Six Sigma, TPM, RCM, Training

Jan 2011Present


The American University in Cairo (AUC)

• Conduct the Industrial Engineering courses at the Engineering and Science Services ESS.
• Designed and delivered 40 leadership & technical skills enhancement training modules.

List of Teaching Courses:
Primavera P6, Quality Management, Lean Production, TPM, Six Sigma, Maintenance Planning & Management, Condition Monitoring, CMMS, Maximo, Reliability Engineering, RCM, FMEA and Problems Solving. Please see my SlideShare profile

Participated in training & coaching the working team from many different companies such as: Schlumberger; British Petroleum; Khalda Petroleum; Petrojet Petroleum; British Petroleum; Toshiba; EGAS; BG; EZZ Steel; Sina Cement; Saint Gobain Glass; RASHID CO, Egyptian Drilling Company (EDC).

Aug 2014Present

Professional Trainer & Author

Please see ☛

I write for leadership development, cultural change, management psychology, and the use of the improvement tools to achieve excellence in various business operations. I'm a Lecturer at The American University in Cairo, and an author of several published international articles. My writing in management appears in Lean Thinking, Industrial Management, and Industrial Engineer.

I teach organizations how to develop new routine of thinking and acting with its employees and form new habits in order for the culture of improvement to be embedded with all employees and throughout the organization.

I provide different ways of training other than classrooms, include workshops, Kaizen events, A3 training, and problems solving.

★★Author of 5 published papers and one book★★ Please see ☛ the Publications section

Aug 2013Apr 2014

Operational Excellence Consultant

Crystal Asfour International

Consultant for the Engineering & Manufacturing sectors. Provide workshops & training for the engineering team on TPM and Lean methodologies; help them find opportunities to improve production performance. Assist crystal processing sector Management to improve operations.
Mentor the use of reliability analysis techniques like failure mode effect analysis and other Lean tools to help design, manufacturing, and quality engineers analyze products and discover potential faults, prevent them, and improve product life time.

• Introduced a Continuous Improvement culture throughout all levels of management.
• Evaluated production bottlenecks using OEE and Mapping techniques and developed action
plans to resolve. Set and monitor performance goals.
• Introduced manufacturing Cells to reduce non value added, batch processing, thus reduce
manufacturing lead times by 40%.
• Improved human resources utilization from 50% to 80% value-added work.
• Developed training and trained key employees on Lean methodology (VSM, one piece flow,
JIT, TPS, FMEA, OEE, quality controls).

Jul 2013Jan 2015


APEX Dubai

Conduct international courses. I conducted a condition monitoring course for Vale Pelletizing Oman (a large Brazillian company for pelletizing).

Mar 2011Mar 2013

Continuous Improvement Leader

Crystal Asfour International

Worked for the Engineering & Manufacturing sectors. Led the Lean culture via associate training
and conducting Kaizen events. Assisted the technical director in change management.

• Defined 280K$ improvements through wastes removal using lean mapping, 5S, and quality.
• Developed VSMs for 10 value streams within building with 8 to 10 kaizens identified for each,
prioritized kaizens. Thus maintained standard work and reduced resources by 30%.
• Failure rates reduced by 20% by established the use of predictive maintenance.
• Implemented 5S and waste walk programs and instituted audits to ensure sustainment
• Designed a performance evaluation system that helped tackle problems, highlight priorities, and make decisions.
• Promoted the use of the maintenance management softwares to handle work orders.

May 2008May 2010

Process Improvement Engineer

Abu Zaabal Fertilizer & Chemical Company AZFCO

A large fertilizer manufacturer. I Worked with the plant managers to train and engage employees in 5S, quality, and total productive maintenance projects throughout the plant.

For the GSSP plant: worked to improve processes (environmental problems, granulation process, operations and material handling). Sourced some parts from overseas sources. Created plant performance reports for the CEO.

For the SSP plant: reduced the cost of transportation and plant downtime whilst reducing maintenance costs.

For the TSP Plant: improve machines inspection to increase the mean time between failures, prepare the spare parts stock plan, improve preventative plans to reduce corrective maintenance.

For the sulphoric acid plant: improve preventive maintenance, reduce failure rates by using the condition monitoring techniques.

• Improved equipment availability for production improved by 25%.
• Saved material handling costs by 30%.
• Improved mean time between failures for critical machines by 50%.
• Recovered plant productivity and increased total monthly sales revenue by 100K$.
• Saved annual maintenance costs by 20K$.
• Reduced changeover time by 50%+ by building and storing "changeover carts" that contained all tools and change parts at point of use.


Sep 2012Jan 2013

International Post-Graduate Certificate

The American university in Cairo & AACE

Certified Cost Consultant from the International Authority of Cost Management.

Sep 2009Jan 2012

Diploma/Professional Program

The American Unievrsity in Cairo

A professional diploma in EM.

Oct 2008Jul 2010

Post-Graduate Certificate

The American Unievrsity in Cairo

A specialization Certificate in IE

Jan 2007


Assiut University

Bachelor of Science in Engineering

Text Section

Publications List

Ahmed Soliman, Mohammed. Hamed. (2014). “The Seven Deadly Wastes and How to Remove Them from Your Business” Amazon

Journal Articles
1) Ahmed Soliman, Mohammed. Hamed. “A New Routine of Culture Change” Institue of
Industrial Engineers IM Magazine MAY2015, VOL.57 Issue 3, USA.
2) Ahmed Soliman, Mohammed. Hamed. “Analyzing Failure to Prevent Problems” Institute of Industrial Engineers IM Magazine Sept2014, Vol.56 Issue 5, USA.
3) Ahmed, Mohammed. Hamed. “Daily Walks Train Future Leaders” Industrial Management IM Magazine Jan2014, Vol.56 Issue 1, P21, USA.
4) Ahmed, Mohammed. Hamed. “Lean Transformation Guidance” International Journal of
Lean Thinking IJLT Jun2013, Vol.4 Issue 1, Turkey.
5) Ahmed, Mohammed. Hamed. “OEE Can Be Your Key” Institute of Industrial Engineers IIE
Magazine Aug2013, Vol. 48 Issue 8, P43, USA.


Professor Doctor Attia Gomaa



Hoshin Kanri, Performance Management, Employee Development, Goals Alignment.

Professional Training
Quality Tools

Pareto, Process Mapping, Control Charts, 5 Whys, Root Cause Analysis, FMEA.

Operational Excellence

JIT, Inventory Reduction, Kanban, Hejunka, Jidoka, VSM, 5S, Takt Time.

Business Process Improvement

Financial Modelling, Cost Management, Business Analysis & Diagnosis, Performance Management.

Industrial Engineering

Manufacturing Engineering, Quality Control, Lean Production, Problems Solving, Six Sigma, Process Improvement, OEE, TPM.


Text Section

Text Section


Jan 2013Present

Certified Cost Consultant CCC

International Authority of Cost Management AACE & AUC
Sep 2011Present

Leadership & Organizational Management for Engineers

The American University in Cairo
Sep 2011Present

Strategic Planning & Change Management for Engineers

The American University in Cairo
Jun 2011Present

Fundamentals of Project Management

The American University in Cairo
May 2011Present

Financial Resources & Procurement Management

The American University in Cairo
May 2011Present

Total Quality Management

The American University in Cairo
Sep 2010Present

Engineering Operations & Change

The American University in Cairo
Jun 2010Present

Cost Management for Engineers

The American University in Cairo
Jun 2010Present

Planning for Engineers

Feb 2010Present

Reliability Centered Maintenance Implementation

The American University in Cairo
Jan 2010Present

Global Maintenance Management

The American University in Cairo
Nov 2010Present

Mechanical Bearing (FAG Bearing Seminar and Mounting& Dismounting Course)

FAG Bearing CO
Oct 2011Present

Computerized Maintenance Management System "CMMS"

BAYAN Training CO
An In-House Training Provided by Asfour.
Dec 2010Present

Valves Selection, Operation, and Maintenance

The American University in Cairo
Oct 2008Present

Planning for Maintenance Operations

The American University in Cairo