Production Engineer
Kemya (SABIC & ExxonMobil JV)
Total years of experience :12 years, 1 Months
Production
• Generate PBR Production & Quality Report in which Production, Right First Time (RFT), Quality Percent is reported to Kemya Management on a Weekly Basis.
• Developed the Manufacturing Excellence Report for the unit where Manufacturing Effectiveness Index (MEI), Overall Performance Index (OPI), Surface Factor, Utilization Factor, Best Achievable Rate (BAR) are reported to Kemya Management on a Monthly basis
• Analyzed process data using Uniformance Process History Database (PHD) to troubleshoot process upsets, optimize utilities consumption, and increase production
• Month End Closing on SAP
o Calculate raw material inventory inside the process, storage tanks and ISO-Tanks
o Raw material adjustment based on actual consumption
o Production write on for PBR finished products
o Bill Of Material (BOM) modification to match true material consumption
Safety
• Developed the Safety Critical Device (SCD) list for the plant
• Participated Transient Operation HAZOP (TOH) for the Regenerative Thermal Oxidizer (RTO) units for both Startup and Shutdown
• Attended Butadiene recirculation line HAZOP
• Developed the alarm management system for PBR finishing.
• Identified major construction defects that could have led to major safety incidents: Missed handrails and holes on PBR pipe rack, Wrong extruder deluge system installation, Lack of safety guards around the balers and around the packaging conveyors chain and sprockets. All of these were fixed by contractor.
Quality
• PBR ISO-9001
o PBR Focal contact for ISO-9001
o Created Raw material record such as ISO-Container weekly report, safety stock inventory
o Developed PBR Quality documents and Records
o Generated a list of Quality Critical Devices
o Granted ISO-9001 certificate on September 2016 after meeting all the requirement and passing the external audit
• Quality Incident Investigation leader for PBR
Sustainability & Environment
• Sustainability Leader for PBR
• Created Key Environmental Variables (KEVs) to monitor and optimize Utility Consumption for example reduced steam consumption going to the extruder.
• Developed equipment energy consumers spreadsheet. Every equipment’s’ energy consumption is calculated and monitored to ensure that Kemya is meeting its sustainability and Saudi Energy Efficiency Center (SEEK) target.
• Generated Regenerative Thermal Oxidizer Emissions Reports
Plant Start-Up & Leadership Activities
• Developed and led the functional testing of RTO Burner Management System (BMS) and the Safety Instrumented Systems (SIS).
• Reviewed and led the functional test of the packaging equipment as part of the contractor pre-commissioning activities.
• Finishing Construction walkthrough leader. My team came up with over 5000 punch items
• Finishing Pre-Start Safety Review (PSSR) and startup leader
• Implemented over 20 process improvement modification
• Styrene Butadiene Rubber (SBR) 30% Model Review
• Set up the crate/pellet serial number for product traceability
• Evaluate PBR assets and convert the current SABIC depreciation method to meet the International Financial Standards (IFRS).
• Participated in assets criticality assessment for PBR plant covering approximately 9000 tags to ensure the best and most efficient reliability methodology (RCM, RBI, RIS and FMEA)
Saudi Student Association, Vanderbilt University Fall 2011-Spring 2013
President
• Organized 4 multicultural events for Vanderbilt/Nashville community, each with about 100 attending
• Supervised 2 sporting events
• Led approximately 10 meetings of officers and members
• Met objective to increase the number of non-Saudi members
While I was in intern, I updated the P&IDs of the resin plants. In the process I learned what the instruments look like. I also learned how these instruments work. I also worked with my supervisor in many projects such as installing the new Differential Scanning Calorimetry Machine and replacing old pumps with newer more efficient ones.
Vanderbilt University, Nashville, TN Spring 2013 Bachelor of Engineering, Major: Chemical and Bimolecular Engineering, GPA 3.550 Minor: Engineering Management, and Chemistry