Khaled Masoud
Mississauga,Canada
Summary
Results-driven Operations & Continuous Improvement professional with over 10 years in manufacturing and process optimization. Led cross-functional teams and executed capital projects to achieve cost savings and efficiency gains. Skilled in Six Sigma and Kaizen methodologies, leveraging data analysis and ERP systems to enhance operational performance.
Overview
11
11
years of professional experience
7
7
years of post-secondary education
Work History
CONTINUOUS IMPROVEMENT MANAGER (EBS)
Hydro Extrusion
Mississauga, Canada
01.2024 - 07.2025
- Lead process engineers and process leads to drive improvement initiatives across departments through a collaborative framework and training road map.
- Improved (EBS) department KPI by 4% through standardization of process parameters and adherence to recipe controls.
- Drove the 5S program across the facility with a proven effectiveness score of 95%.
- Carried out Value Stream Mapping on a fabrication line that resulted in 7% higher efficiency.
- Partnered with maintenance team to reduce equipment downtime via structured Kaizen workshops and team collaboration.
- Led capital and non-capital projects, including the replacement of handling systems that reduced process waste by 2%.
- Supported quality Improvement by reviewing customer claims and facilitating A3 corrective action plans to reduce defects.
- Managed transfer of products from sister plant to Mississauga plant, establishing control parameters for over 120 product shapes.
- Prepared capital project packages supported by forecasted return on investment and benefit analysis to guide decision-making.
- Forecasting plant supplies and achieved cost reduction target of $100K in 2024.
- Analyzed shift-to-shift and operator-to-operator performance using visual bar charts and control charts to identify improvement opportunities.
- Worked with engineering department and central procurement to develop FAT and SAT for a new design of equipment.
SR. PROJECTS ENGINEER
Hydro Extrusion
Mississauga, Canada
07.2023 - 01.2024
- Coordinated with OEM suppliers to procure and implement new equipment designs for projects totaling over $3M, enhancing operational capabilities.
- Oversaw installation and testing of three automated sample saws, improving safety standards and line recovery by 1.5%.
- Managed and executed safety projects, installing sensors and guarding systems, and conducting comprehensive risk assessments to ensure compliance and safety standards.
- Introduced temperature control systems on die ovens, extending tooling lifespan, enhancing process reliability and reducing tooling failure rate.
- Led cross-functional teams on complex engineering projects.
- Conducted risk assessments and developed mitigation strategies for projects.
PROCESS ENGINEER
Extrudex Aluminum
Woodbridge, Canada
09.2022 - 07.2023
- Successfully achieved 5% of productivity improvement (kg/hr) on 80% of top runner dies and continue working on lesser volume dies based on their KPIs.
- Developed report identifying top runner dies for each press, established baseline performance, set target productivity and scrap rate for the year, and implemented action plans to achieve those targets.
- Enhanced extrusion parameters to achieve optimal performance and efficiency. and record results, and benchmark to baseline and target KPIs.
- Identified causes of variation and production downtime, measured current indicators, and assessed their alignment with nominal KPIs.
- Test dies performance on the line by observing pressure, speed and temperature, reflecting product finish.
- Collaborated with data analysts to create automated die change control report, streamlining the reporting process.
- Conduct monthly training presentations with production team to discuss practices, achievements, and targets that align with the organization vision.
- Commissioned and tested the performance of newly installed quick response smart container.
PRODUCTION SUPERVISOR & PROCESS IMPROVEMENT PROJECTS LEAD
Aluminum Products Co.
Dammam, Saudi Arabia
07.2016 - 08.2022
- Led 45 employees in extrusion department to achieve common objectives aligned with organizational goals.
- Achieved project objectives of extrusion scrap rate reduction by 1.5% and productivity improvement by 3% in 2020.
- Successfully reduced energy consumption by 5% in presses production lines, targeting 568 kwh/ton -10% vs 2018 in electricity and 135 Lt/ton -10% vs 2018.
- Led functional team and reported monthly on status of 26 cost-saving projects, including metal savings, machine downtime, powder and chemicals consumption, packaging materials, and labor costs.
- Developed optimum extrusion recipes for 50 top running and high load dies in 2020 and 2019.
- Developed optimum extrusion recipe for 20 top running anodizing dies in 2020.
- Analyze theoretical scrap rate, extrusion ratio, difficulty factor and press productivity (kg/hr) for new projects with existing or new dies in addition to die manufacturing cost.
- Introduced bar code field on work orders to improve accuracy of reporting production data by operators on the line.
- Minimized production cards paper work to half and redesigned to a one comprehensive work order.
- Acted as QC manager, overseeing quality control processes and team operations, conducting daily internal rejection analysis, tensile tests on produced batches, and preparing first sampling reports while addressing customer complaints.
ASSISTANT PROJECT MANAGER
Abdulla Fouad Holding Co.
Khobar, Saudi Arabia
04.2014 - 06.2016
- Completed delivery and installation of 30,000 Lenovo workstation for end users of the biggest oil company in the region, including offshore sites.
- Coordinated weekly delivery plan with customers, achieving monthly average Schedule Performance Index (SPI) of 1.1.
- Developed effective project management tracking tool.
- Conducted operational risk assessment with response strategies and monitored progress through risk register log.
- Developed incentive scheme for team members to achieve targeted KPIs.
- Implemented quality check lists for parts and machines.
- Assessed customer feedback through survey emails and addressed requirements.
Education
PRINCIPLES OF OPERATIONS & SUPPLY CHAIN MANAGEMENT -
University of Toronto, School of Continuing Studies
06.2025 - 08.2025
MASTER OF SCIENCE - PROJECT MANAGEMENT
University of Hertfordshire
Hatfield, United Kingdom 09.2012 - 09.2013
BACHELOR OF SCIENCE - MECHATRONICS ENGINEERING
AMA International University
Bahrain 09.2007 - 08.2013
Skills
- Six Sigma
- DMAIC
- Lean 6σ
- Projects Scheduling
- Teams development
- Leadership
- Strategic road maps
- Contracts management
- Projects governance
- Data analysis
- Projects budgeting
- ERP systems
- Process Control
- Risk Management
- Metallurgy
- Kaizen Practices
- MS Project
- Materials management
- Suppliers management
Headlines
OPEX & CI - CLSSBB©, Supply Chain & Ops Mgt.©, MSc Project Management©
Personal info.
Nationality - Canadian
Marital status - Married
Travel status - Willing to relocate
License and Certifications
CERTIFIED LEAN SIX SIGMA BLACK BELT - Council for Six Sigma
INDUSTRIAL METALLURGIST, ALUMINUM METALLURGY - American Welding Society
FIRST AID CERTIFIED TRAINING - Hydro Extrusion
FRONTLINE LEADERSHIP BOOT CAMP - Hydro
MANAGING UNIONIZED ENVIRONMENT - Queens University LRC
MANUFACTURING EXCELLENCE COURSE - Hydro Extrusion
CONTINUOUS RELIABILITY IMPROVEMENT COURSE - Hydro Extrusion
OCCUPATIONAL HEALTH AND SAFETY ACT - Workplace Safety & Prevention Services
AGILE IN PROGRAM MANAGEMENT OFFICE - Project Management Institute "PMI"
CERTIFIED INTERNAL AUDITOR - TUV NORD
"CAPM" CERTIFIED ASSOCIATE IN PROJECT MANAGEMENT
Project Management Institute "PMI"
References
Available upon request.
Timeline
PRINCIPLES OF OPERATIONS & SUPPLY CHAIN MANAGEMENT -
University of Toronto, School of Continuing Studies
06.2025 - 08.2025
CONTINUOUS IMPROVEMENT MANAGER (EBS)
Hydro Extrusion
01.2024 - 07.2025
SR. PROJECTS ENGINEER
Hydro Extrusion
07.2023 - 01.2024
PROCESS ENGINEER
Extrudex Aluminum
09.2022 - 07.2023
PRODUCTION SUPERVISOR & PROCESS IMPROVEMENT PROJECTS LEAD
Aluminum Products Co.
07.2016 - 08.2022
ASSISTANT PROJECT MANAGER
Abdulla Fouad Holding Co.
04.2014 - 06.2016
MASTER OF SCIENCE - PROJECT MANAGEMENT
University of Hertfordshire
09.2012 - 09.2013
BACHELOR OF SCIENCE - MECHATRONICS ENGINEERING
AMA International University
09.2007 - 08.2013