Maintenance manager
Maaden Phosphate
مجموع سنوات الخبرة :29 years, 6 أشهر
Accomplishes department objectives by managing staff; planning and evaluating department activities.
Maintenance manager mission is to handle the upkeep of a company. It is not a simple task due to many factors! The task has to consider production stability, reliability of the machines, environment, etc.
In my opinion when Maintenance Manager join any new company he has to focus on:
1. Risks: any corporation has at least one weak point, or relatively some weak points; all the risks should be assessed, action plan should be established and implemented till resolve all the risks possibilities.
The risks could be: certain machine/area problems, lack of spares, lack/excess of manpower, weak maintenance program that could obstacles the production, etc.
2. Check, re-design, to improve the maintenance programs that assures stable machine running according to desired production rate.
3. Preventive/Predictive maintenance programs: there is no contradiction between the two systems, both are required! Apparently it could be costly, but in fact the opposite is true, it is a very good investment tools and it saves any factory from many unnecessary breakdowns.
PM/PdM is not only tools, it is: qualified staff, spare parts studies, shutdown plans, root cause analysis, & pro-active maintenance, good coordination with material department to secure spare parts providing min-max for strategic/special/normal items.
4. Staff training and new hires: the market needs puts a very big responsibility on the maintenance team shoulders and without staff training and secure the company needs with new qualified staffs it will be one of the impossible to achieve company’ goals and to achieve that it requires a big efforts and shoulder to shoulder support between Maintenance & HR departments.
5. Research for new equipment: so many would say it is the Project or Engineering department job! In fact the maintenance team who feels first for the need of new equipment or method and then the other department could complete the mission.
6. Integrated safety: again it is not Safety department mission it is everyone mission, it is safety for machines, humans, products, and customers at the end. It enforced the industry requirements.
7. Managing budgets and expenditures: it is the meaning of all what is mentioned above “The Cost”, how will you manage the annual cost? How will it affect the Shareholders business? We can say any company as a concept is focusing on the cost of the famous 5Ms equation:
Man + Machine + Method + Material + Management
In technical fields I have faced many challenges i.e., fabrication of large size impellers, repairing of vertical mill gearboxes, replacement of main process fans, cooler maintenance, fabrication of heavy duct works, machining of several and complicated items, ESP maintenance, power plants O & M programs, utility tasks O&M, mechanical and electrical workshop activities, garage and heavy equipment activities, shutdowns planning, load shedding/sharing, and others.
Financial field: preparing department budget, cash flow studies, cost reduction reports, etc.
Administration & HR activities: new hiring, staff training, organization structural building and adjustments, etc.
NLSupervision has several Maintenance & Operation contracts in some cement plants in Egypt and one of the big challenges to increase the productivity is to have healthy equipments to get a stable running factory and productivity. Since I started here I put a strategy for “how to drive the plant and avoid to be driven by the plant”, a strong vibration system should be applied starting from: Measuring tools selection. Technicians training. Building the machines database. Applying routine checking programs. Reporting our clients for recommended actions and remedy.
Because we have several clients we started to collect the needed information regarding how to globalize our mission, the action plan brief: Upgrading our vibration software from single user local license to WAN multi users’ license. Our team and technicians will be spread all over different locations with their vibration measuring tools and through the internet we will be able to read/edit the collected data and communicate with them for the suitable action. We will provide to our client an access to read “without editing” the vibration data. Also we can control and analyze the vibration from different locations from one place.
Establish new predictive maintenance section that belongs to maintenance department. Selecting the required vibration tools and accessories, and training vibration technicians. Building vibration routes database all over the plant, we have a 53 routes that include a 995 critical machines to be tested. We are measuring and analyzing around 1000 machines (around 8000 measuring points per month).
Advanced vibration analysis (Spectrums, waveforms, phase readings, cost down/rise up measurements, bump test, impact test "using force hammer", Nyquist diagram, Peak-Vue, setting alarms for determining vibration severity, etc.)
Impeller static and dynamic balancing in one and two planes.
Laser alignment, and dial indicator alignment (Two reversible indicators).
Acting as PM (preventive) inspection supervisor for following up and visually inspection of machines condition through a pre-prepared machine check list and leading a group of mechanical and electrical inspectors.
Mechanical maintenance shift engineer for plant trouble shooting.
Participating & leading Quality Assurance teams during Kiln shutdowns.
Participation in Quality circuits for curing chronic problems.
As a team member in studying the maintenance department annual budget & evaluating machine cost analysis for cost reduction
Mechanical inspector for 03 years:
Doing all the required inspection activities in cement plants including vibration monitoring.
Mechanical Maintenance engineer for 02 years:
Maintenance mechanical engineer in Crusher area, & Raw mill area.
X-Ray inspection of tires.
Quality control statistic calculations for all process steps
Machining: most types of items machining, shafts, gears, flanges, etc.
Fabrication: many types of metal forming works.
Advanced vibration analysis
Studied different subjects in mecanical, production, & industrial engineering.
