1. Steven Foster
Curriculum Vitae Cover Sheet
Current Position: Head of Maintenance (Group)
Current Company: United Cartons Industry Company (UCIC), Jeddah, KSA
Education: BEng Honours Degree (2:2) in Manufacturing Systems with
Management
BTEC National Diploma in Mechanical & Manufacturing
Engineering
City & Guilds in Mechanical & Manufacturing Engineering
Accreditation: Six Sigma Black Belt
Technical Skills: FMEA, DOE, SPC, VSM, Root Cause, DMAIC, Process
Mapping, Pareto, Chi-Squared, Fish Bone Diagrams,
P.U.W.E.R, L.O.L.E.R, cGMP, Manual Handling, 5's,
Kan-Ban, Cellular Layouts

2. Personal Profile:
Experienced and innovative Engineering / Maintenance Manager who leads by example, with Production / Projects
Engineer experience and also apprentice trained engineering skills across a wide range of machine expertise
Highly Articulate, confident and persuasive team-builder, able to motivate and communicate to both upper
management and shop floor personnel
Excellent planning, costing, sourcing and installation skills of new plant machinery, and the relocation of existing
machinery utilizing Permits to Work (General, height, C.S.E & hot) , risk assessments, inductions and training
schedules
Excellent team person either as part of or leading a team, I can also work alone using my own determination,
creativity and technical skills to problem solve
Focused, but flexible approach to projects, maintenance (both planned and breakdowns) and work well under pressure
Honours Degree in Manufacturing Systems with Management (2:2 BEng)
Experience:
Managing three plants maintenance departments with a complete team of 72 technical staff, control of a R & M
budget of SR32M, and capital projects of SR5m.
Driving down unscheduled breakdowns, improving PMI schedules and control of spare parts and the reduction of
inventory. Managed successful shuts in Jeddah during both Ramadan and Hajj (EID) holidays
Managed 9 major shuts on the Holcim site – ranging from a Silo clean out to a full cement mill, utilising both Holcim
Mill’s team and a large number of contractors. All shuts have come in under / on Budget with no extended delays.
Cement Mill 1 Shut came in 4 days early and $150k under budget
Excellent safety record – zero LTI’s, MTI’s (Medically Treated Incidents) & 1 FAI (First Aid Incident), fully trained
ICAM investigator and Completed Safety Leadership course (Internal).
Six Sigma Black Belt, working on projects (using DMAIC) in both lean (Value Stream Mapping) and Six Sigma
Design of Experiment (D.O.E) on wear ring strip production (targets of 75% waste reduction ($20K) and increased
capacity ($350K)) from raw material through to dispatched finish goods for customers. Six Sigma project on material
defects (tube production) and causes.
Great analytic skills in gathering raw data and transferring, filtering and analysis to reporting
Proficient in the use of all Microsoft packages, S.A.P, AutoCAD, Minitab, Sigma-works, Process Modelling
Experienced at working on projects from rough concept designs to final installations, including writing documentation
for Factory Acceptance Trials (F.A.T) and Site Acceptance Trials (S.A.T), Change Control and validation documents
to current F.D.A regulation
Good budgeting skills, looking after large ($3.2m) and small ($650K) revenue budgets, including writing Capex's for
the securing of funds, and controlling a tooling spending budget ($130K) for the financial year (2 years running)
Delivered and installed (as a team leader or part of team) 18 machines to site, including 5 manual handling associated
projects
Fully trained risk assessor, manual handling trainer and worked for the Health & Safety department on an 18 month
secondment, carrying out risk assessments for the engineering department and producing a register, which lead to
implementing manual handling changes within the factory and offices
Used a number of lean manufacturing tools to improve the company’s production problems, including Value Stream
Mapping, 5's, cellular production (grouping families of parts), Kan-Ban systems, process flow (reduction of rework &
parts movement) and waste reduction
Carried out quality testing on products and customer returns, producing detailed reports on the findings
Designing of jigs and fixtures for machines and general working, including manufacturing proto-type models

3. Achievements:
United Cartons Industry Company (UCIC), Jeddah:
Reduced downtime across the plants: P1 – From 3.4% to 2.6% (YTD), P2 – From 5.7% to 4.3%, P3 – From 2.7% to
2.3%
R & M Budget gone from SR1.1m over budget (2015) to SR2.47m under budget (YTD)
Reduction of spare parts in stores: P1 – 1.5%, P2 – 1.4%, P3 – 2.2% by reviewing and setting Min / max stock levels
Reduction of inventory (old 2004 to 2013 & Obsolete) P1 – 40.5% (SR1.66m), P2 – 49.5% (SR0.7m), P3 – 55%
(SR0.5m)
Reduction of consignment stocks: P1 – 36% (SR0.4m), P2 – 23% (SR0.12m). P3 – 14% (SR0.36m)
Holcim (New Zealand) Ltd, Westport:
Started off as Auxiliaries Maintenance Manager, before being promoted to Maintenance Manager – Mills, now
Maintenance Manager – Kilns / Mills
Running a department of 3 mechanics, 4 fitters (Aux Dept.) and 5 fitters, 4 labourers (Mills dept.), now running a
team of 18 maintenance personnel
Working closely with Production Supervisors and operations to ensure better running of the plant via good planned
maintenance
Successfully running a maintenance budget of $3.2m (2012) coming in $60.5K under budget, with a $3.713m budget
for 2013, and now running a budget of $10.3m , currently standing at $404,000 under budget YTD (Taken on 30th
nov
2013)
Completed 9 shuts on site, bring them in on time / early and with in budget
Safety record: Zero LTI’s, Zero MTI’s and 1 FAI (First Aid Incident) – Contractor burnt hand on hot molten steel
whilst gas cutting bolts off
Completed ICAM investigator course – to carry out high and medium level investigations on site and other Holcim
sites when major incidents occur
Safety leadership Development (Parts 1 & 2) – Driving safe working within the group and leading teams / individuals
through safety on Holcim’s “Zero Harm Journey”
Practical Leadership Skills 1: The Self-Aware Leader
4 Quadrant Leadership – New Zealand Institute of management
Stepped in as Acting Engineering Manager whilst Engineering Manager has been away
Amcor Kiwi Packaging (Hastings)
Running the Maintenance department (5 staff, plus numerous contractors)
Planning the daily, weekly, monthly maintenance, annual shutdowns
Running an R & M budget of $1.3m, coming in under budget ($50,000), planning new budgets and forecasting
Writing all Capex, User requirement Specifications for new capital and running the project management of them
(new machine $2.3m, trim master $152K)
Reduced maintenance break downs from 5.5% to 2.8% (Mechanical) & 1.356% to 1.0% (Electrical)
Installation of the new corrugator conveyor system on time and under budget
Installation of the new load former and conveyor system for the gluer on time
Reduction of set-up times on the machines ranging from 2.89% to 37.37%
Increase in productivity on the machines ranging from 3.3% to 11.8%
Reduction in the machine downtimes from 1% to 5.8% across the factory
Successfully run the converting department (15 people) as acting supervisor when the main supervisor has been away
and also acting supervisor for maintenance (6 people) when the supervisor has been away
Run successful fish bone and FMEA problem solving teams leading to the above successes
Carried out numerous studies, in waste reduction, production efficiencies, material movement and plant layouts
Trelleborg Sealing Solutions
Waste reduction project (part of Six Sigma Black Belt project) savings of GBP 70K / yr.
New pallet loading CNC machine for milling section: Cycle time reduction success with cost savings of GBP46K/yr.
Machine Study (increasing speeds & feeds) on CNC cells, improved cycle time on bush work by 24.5%
Sourced, purchased and packaged / shipped machinery for plant in china, (2 CNC's, 4 other small machines) all
successfully installed and working.
Introduced a new mandrel manipulator in the wrapping extract process to handle large (+40kg) mandrels off the line
into the extract machine, removing the need for the operator to handle them
Extended the marine crane system as part of the large wrapping project
Installed 9 new machines and moved 12 existing machines around the Rotherham site without any major incidents /
accidents

4. Smith & Nephew Medical Ltd
Single Minute Exchange of Dies (SMED): Cost savings GBP66K / yr., reducing die cutting changeovers from 5 hours
to 2 hours, two fold projects also reduced manual handling risk assessment score from 165 to 30
Reject Bin Improvement project: Cost savings of GBP44K / yr.
Manual Handling: Large roll manipulator for Allevyn line; picked up, rotated and loaded large rolls of film (+80Kg)
on to the machine
Manual Handling: Large roll manipulator for Flow wrapping section, picked up rotated and loaded rolls of vacuum
film (80Kg)
Vacuum bag handling unit to paste division: Moving 25kg bags of material from clean to dirty side of airlock (4 x
250kg pallets at a time)
Various small changes to working practice within the Engineering department reducing lifting of heavy awkward
items whilst bending, twisting and crouching in machines
Installed (using a team of riggers) 15 new machines, and moved 7 existing lines around within the Hull site without
any major incidents / accidents.
Euro Power Hydraulics Ltd
CNC Cellular project: Grouped families of parts and set CNC section up in to small cells: reducing set-up times per
machine. Saving GBP18K/ yr., removed 2 heads from the section saving GBP38K/ yr.
5's on hose assembly line: Reduced time looking for tooling / parts. Increased production capacity by 6%, removing
need for overtime costs. Cost saving of GBP22K / yr.
Career History:
2015 to present United Cartons Industry Company (UCIC), Jeddah, KSA – Head of Maintenance (Group)
2011 – 2015 Holcim (New Zealand) Ltd Cement Works, Westport – Maintenance Manager – Kilns / Mills
2007 - 2011 Amcor Kiwi Packaging (Hastings): Process Improvement Engineer, then Maintenance Manager
2005 - 2007 Trelleborg Sealing Solutions (Rotherham), Rotherham: Six Sigma Black Belt, Production
(Projects) Engineer
2001 - 2005 Smith & Nephew Medical Ltd, Hull: Manufacturing Projects Engineer
1999 - 2001 Euro Power Hydraulics Ltd, East Yorkshire: Quality Projects Engineer, Continuous
Improvement Engineer, Process Engineer
1997 -1997 Reiter Automotive (6month University placement): Technical Assistant
1998-1998 British Steels Technology Centre (7 month University placement): Finite Element
Analyst & Plant Condition Monitoring Analyst
1988 - 1991 Taylor Valves Ltd, Huddersfield: CNC Setter / Operator
1985 - 1988 Case Tractors, Huddersfield: Apprentice Engineer, then CNC Setter / Operator
Education:
1995 - 1999 University of Bradford: BEng Honours Degree (2:2) in Manufacturing Systems with
Management
1993 - 1995 Huddersfield Technical College: BTEC National Diploma in Mechanical &
Manufacturing Engineering (7 distinctions, 17 Merits)
1985 - 1993 Huddersfield Technical College: City & Guilds:-
General Technology & Mechanical Engineering Practices (Pass & Credit)
Basic Engineering & Mechanical Production Technology (Pass & 2 Credits)
Basic Engineering Technology (Pass & Credit)
Mechanical Engineering & Process Experience (Pass & Credit)
RSA Typewriting Skills stage 1 (Pass)
Engineering competence & technology to NC / CNC part programming level 3 (5 Passes
& 8 Credits)

5. Personal Details:
Title: Steven Foster
Date of Birth: 13th
January 1969
Address: Arabian Homes – Sierra Village – 8b Deyna
Kaheel Alazdey St. 96
Al Zahra District
Jeddah, KSA
Telephone No: +966 12 662400 Ext. 2712
Mobile No: +966 554448562
E-Mail: stevefoster13@hotmail.com
stevefosterholcim13@icloud.com
steven.foster@ucic.com.sa
Skype Address: fozndebs
Skype for Business: steven.foster@ucic.com.sa
FaceTime: stevefosterholcim13@icloud.com
Marital status: Married to Debbie with 1 daughter aged 10 year’s old (residing in Jeddah)
Residence Status: New Zealand Citizenship (was permanent resident), KSA Resident (Iqama), British Citizen
Driving license: Clean (New Zealand, UK licenses, Saudi Arabian)
Leisure Activities: Enjoy playing golf and cycling (Rode Tour of the Bay 50Km, Tour De Beautiful 25km,
Taupo flyer 100km, around Taupo 40Km stage)
Going to the Gym, ran 3rd
stage of Buller marathon this year
Traveling
Spending time with my daughter
Watching all aspects of sport both at amateur and professional levels
References: All certificates and references available
Reference contact details for Steve Foster
Mohnish Rikhy
General Manager
United Cartons Industry Company (UCIC)
Jeddah
Tel: +966 12 2244200
Mobile: +966 506681899
E-mail – rikhy@ucic.com.sa
Clark Nelson
Engineering Manager
Holcim NZ LTD
Cape Foulwind
Tel: +64 3 7895834
Mobile: +64 21665187
E-mail: clark.nelson@holcim.com
Paul Coleman
Shipping Manager (was Engineering Manager until Jan 2013)
Holcim (New Zealand) Ltd
Cape Foulwind
Tel: +64 3 7895871

6. Mobile: + 64 212427842
E-mail: Paul.Coleman@holcim.com
Dave Morrison
Manufacturing Manager
Amcor Kiwi Packaging (Hastings)
Meihana Street
Hastings
Tel: +64 6 9748095
Mobile: +64 21461720
E-mail: Dave.morrison@pllnz.co.nz
Barry Redfearn
Operations Manager
Trelleborg Sealing Solutions Rotherham
Bradmarsh Business Park
Rotherham
South Yorkshire
S60 1BX
Tel: 00 44 1709 789822 (Direct)
Tel 00 44 1709 789800
Fax: 00 44 1709 374819
Mobile: 00 44 7747066178
E-mail: barry.redfearn@trelleborg.com

7. Mobile: + 64 212427842
E-mail: Paul.Coleman@holcim.com
Dave Morrison
Manufacturing Manager
Amcor Kiwi Packaging (Hastings)
Meihana Street
Hastings
Tel: +64 6 9748095
Mobile: +64 21461720
E-mail: Dave.morrison@pllnz.co.nz
Barry Redfearn
Operations Manager
Trelleborg Sealing Solutions Rotherham
Bradmarsh Business Park
Rotherham
South Yorkshire
S60 1BX
Tel: 00 44 1709 789822 (Direct)
Tel 00 44 1709 789800
Fax: 00 44 1709 374819
Mobile: 00 44 7747066178
E-mail: barry.redfearn@trelleborg.com