Maintenance manager
Suez Cement company (kattameya plant) , Heidelbergcement group
مجموع سنوات الخبرة :20 years, 7 أشهر
Head of Maintenance department of one dry process Cement production line including 7 sub departments (Mechanical, Electrical, Automation, Workshop, Methods and planning, Civil and Mobile equipment departments):
• Ensure the achievement of plant maintenance targets: Safety, Reliability factor, MTBF, Maintenance cost, Warehouse inventory, Productivity, Thermal and Power consumption.
• Achieving the above mentioned targets through the application of Total productive maintenance (TPM) management system including :
1- Develop the annual maintenance plan (Tasks, Cost and Manpower) as per approved SPI.
2- Ensure proper planning and scheduling for daily, weekly and major outages tasks.
3- Ensure regular and efficient as per plan :
• Inspections (On & Off) covering all plant equipment.
• Condition base monitoring (CPM) including Vibration measurements and analysis, Oil analysis.
• Stoppage analysis for all plant equipment.
• Root cause failure analysis (RCFA) for the major equipment.
4- Ensure daily, weekly and major outages tasks Execution as per planning in terms of Time, Manpower and cost through Short interval control system (SIC).
5- Ensure and control maintenance cost spending and warehouse inventory VS plan (Budget).
6- Ensure publishing of daily, weekly and monthly maintenance reports.
7- Managing the whole maintenance cycle through SAP computerized maintenance system (CMMS) :
• Developing the annual maintenance cost on SAP.
• Developing the inspection plan on SAP having the Inspection work orders (IWO).
• Creating the notification and define in it the priority and request start date including: (N5 inspection notifications as outcome from inspections, vibration and oil analysis, N1 maintenance request as outcome from production requests, stoppage analysis and RCFAs corrective actions, N2 down time failure).
• Creating Work orders (WO) Standing and regular including spare parts reservation and manpower.
• Work order approval.
• Work orders and notification closing.
• All plant equipment history to be logged on SAP with the cause of stoppage.
8- Ensure define of known list of plant critical equipment as per standard definition.
9- Ensure proper management of spare parts through well defined spare parts policy using plant bill of material (BOM).
10- Ensure developing of resource skills matrix for maintenance staff white and blue collars for defining their training needs.
11- Ensure Define skills required for each task to develop multi skilling team.
12- Ensure developing standards and specifications for each task for proper planning.
13- Ensure developing of Microsoft project (MSP) for major outage tasks in details including critical path with the time, manpower and cost for each single sub task.
14- Ensure proper P1 release on SAP for requisitions as spares PRs to have the correct Specs, drawings and service PRs to be well defined for subcontractors, using the evaluation form for subcontractors.
15- Ensure the commitment to the Equipment daily stoppage plan (PM daily stoppages).
16- Ensure proper planning and execution for CAPEX (major projects).
17- Define measurable target for maintenance departments managers (Mechanical, Electrical, PM, ….).
Head of mechanical department of one dry process cement
production line including :
Work
experience
* Ensure the availability and trouble free operation of all Mechanical
Equipment in the plant.
* Attend daily meeting and co-ordinate daily activities with the production
and Maintenance personal.
* Review operation and maintenance shift reports on a daily bases and
investigate Reasons for equipment downtime.
* Follow up daily tasks distribution planned (PM stoppages) and routine
tasks following their proper execution.
* Follow up the work order issued from all areas regarding to (Labors,
spare parts, External services) by using PM-PS Module SAP.
* Ensure that all activities are executed according to planned maintenance
schedules with priorities.
* Assist in planning and execution plan major maintenance projects and
develop of Capital investment recommendations within the process area.
* Assist in preparation of budget for Mechanical maintenance activities.
* Assist with training activities as required by his people with maintenance
manager.
* Ensure that proper housekeeping and safety regulations are followed.
* Manage and improve Labor productivity (man-hours/ton cement).
* Analyze total down time for specific equipment/year, due to Mechanical
breakdown (HRS)
* Analyze number of Mechanical breakdowns for specific equipment per
year.
* Manage and control cost of spare parts (L/ton cement).
* Manage and control cost of operative assistance and conservative
maintenance/year.
* Follow with PM and procurement departments spare parts requested
(specs, quantities and vendors)for mechanical department to ensure spare
parts availability parallel with optimizing warehouse inventory.
Mechanical field maintenance of kiln area including :
* Supervise, execute and follow up all the mechanical maintenance
activities on site according to the planned maintenance schedules through
the work orders.
* Developing the daily, weekly and overhaul Maintenance Schedule.
* Analyze equipment failures to determine causes, develop and recommend
solutions.
* Follow up the program for preventive / proactive maintenance actions
according to equipment availability and performance.
* Flow kiln area spare parts in warehouse regarding availability and specs.
* Ensuring that activities adhere to planned cost and timeline.
Supervise, execute and follow up all the sheet metal works activities in
the plant site according to the planned maintenance schedules through the
work orders.
* Supervise, execute and follow up all fabrications requested in the
workshop as drawings according to the planned maintenance schedules
through the work orders.
* Ensuring that activities adhere to planned cost and timeline.
* Execute all safety corrective actions on site.
• Monitor all plant Equipment by Conditioned based monitoring (CBM), Preventive, proactive and reliability maintenance and lubrication.
• Execute vibration measurements for plant equipment as per vibration schedule plan.
• Taking oil samples for analysis as per oil analysis plan.
• Execute vibration analysis with corrective actions.
• Issue weekly vibration report with corrective actions.
• Issue monthly oil analysis report with corrective actions.
• Planning for daily, weekly and major shutdown tasks ensuring proper scheduling for the tasks and the required spare parts, tools and manpower for execution.
• Execute balancing jobs for the fans.
• Execute alignment jobs for the coupling (laser alignment).
• Participate in the stoppage analysis define the root cause and corrective actions.
• Create on SAP work orders and service purchase requisitions.
University education : Last graduation: Bachelor’s , power mechanical engineering faculty/university :faculty of engineering in Cairo, power mechanical engineering, CAIRO UNIVERSITY Date of graduation: 2003 Overall grade : good Project grade : very good