Maintenance Planning Engineer
Tasnee Petrochemicals
مجموع سنوات الخبرة :15 years, 11 أشهر
Good experience in Maintenance Planning and Extensive working knowledge on Computerized Maintenance Management system SAP R/3 system in PM & MM module.
•Experiences on SAP PM modules such as:-
•Notification and Work orders.
•Capacity planning
•BOM, Equipment, Functional Location creation and updation.
•Equipment task list creation.
•Creation and changing of Maintenance Item, Maintenance Plan.
•Scheduling Maintenance Plan.
•Monitoring MTBF, Equipment availability, Man-hour utilization, back log, Schedule attainment.
•Experiences on SAP MM modules such as:-
•Purchase Requisition.
•Purchase Order.
•Service Entry Sheet.
•Critical Spare Part Status.
•Creating material reservation and checking status of material like material availability, goods movement etc.
Planning and scheduling of daily preventive maintenance, corrective maintenance and shutdown maintenance activities based on priority and resource constraint.
Scheduling Plant/ Unit Shutdown maintenance activities in MS Project & preparing daily shutdown progress report.
Identify resources (manpower, materials and services) and making sure of their availability as per job schedule, and also listing of detailed steps and logical sequence of tasks.
Creation of Task list, Maintenance plan in SAP for preventive maintenance activities to be carried out on plant equipment’s.
Ensure preventive maintenance schedules are called and executed accordingly.
Ensure work is planned with realistic completion dates taking into account material delivery lead times, job priority, and resourcing constraints.
Review of backlog and reallocating outstanding maintenance work to future schedules based on priority and resource availability.
Prepare work packages for major and unit shutdown works that is complex and requires numerous coordination activities including bundling of related jobs.
Monitoring and follow up with purchasing group to ensure that Critical Spare parts in hand quantity is always more than reorder point and to avoid zero stock.
Preparing Monthly Cost Report (warehouse stock items consumed, direct charge materials & external services) and comparing it with approved budget so as to ensure maintenance expenses do not exceed the approved budget.
Preparation of Monthly Maintenance Report (Key Performance Indicators, Material status, PM status). Identify shortfalls in performance including areas of improvements.
Working on Maintenance Cost Optimization programs.
Preparing scope of work for contract services, evaluation and finalization of contract services.
Review of spare parts stock level (reorder point, max level, safety stock) based on identical equipment installed, failure rate & lead time.
Review and identify spare parts other than two year operational spare parts which are critical and were not ordered (no SAP material number), also creating SAP material number for them.
Check and review all notifications raised to verify adherence to established quality standards and minimum data requirements.
Convert risked approved and scoped notification into a work order.
Planning and scheduling of all Instrument preventive maintenance, corrective maintenance and shutdown maintenance activities and monitoring them so that they meet their scheduled target date.
Creation of Task list, Maintenance plan for preventive maintenance activities to be carried out on plant equipment’s.
Ensure preventive maintenance schedules are called and executed accordingly.
Liaise with Subject Matter Experts, Operations and Maintenance in the initial job scoping supplemented with history, standard job procedures and local knowledge where required.
Collect all related information for the safe and efficient execution of the task. This includes Technical reports, Inspection Reports from Subject Matter Experts, Root Cause Analysis Reports and the like; its attachment to a work order.
Perform site verification and visits for critical and major maintenance work.
Identify resources (manpower, materials and services) and making sure of their availability as per job schedule, and also listing of detailed steps and logical sequence of tasks.
Monitoring and follow up with Purchasing group to ensure that Critical spares parts in hand quantity is always more than reorder point.
Prepare Cost Estimates for a particular maintenance work and ensure maintenance costs during the planning stage are kept within targets.
Prepare yearly budget for Asset maintenance and monitoring it to assure budgetary compliance.
Prepare a reasonable work duration estimate based on the shortest period to execute the work whilst taking into consideration production operations windows.
Interact and engage with all stakeholders for job execution, that is, Operations, Engineering and Procurement.
Ensures work are sub tasked to other disciplines (Mechanical, Painting, Scaffold, Insulation, Crane and Rigging) for further planning and scoping.
Review associated equipment or Instrument loop Preventative Maintenance work orders for possible job bundling.
Carry out a structured risk analysis of critical jobs to ensure that this goes according to plan.
Review work order safety, costs, scope and timing that is consistent with Work Planning Quality standards.
Prepare work packs for major and Unit Shutdown works that is complex and requires numerous coordination activities including bundling of related jobs.
Preparation of Monthly Maintenance Report (Budget, Key Performance Indicators, Material status, PM status). Identify shortfalls in performance including areas of improvements.
Ensure work is planned with realistic completion dates taking into account material delivery lead times, job priority, and resourcing constraints.
Review of backlog and reallocating outstanding maintenance work to future schedules based on priority.
To make sure the appropriate use of CMMS systems (SAP) that are accurate, user friendly and fully utilized by all sections to continuously improve the integrity and reliability of the complex.
Reviews job methods and procedures, manpower utilization and make/recommend changes to improve work quality and reduce maintenance cost.
Develop and implement programs for effective control for warehouse stock inventory and continually improve the performance of the plant in general maintenance department in particular.
Applies advanced knowledge of inventory management principles to keep inventory and its carrying cost at an optimum level.
Visiting Client site and based on scope of work preparing Cost Estimate and Schedule of the project.
Checking, verifying and reviewing engineering & construction documents like P&ID, instrument loop drawings (ILD), instrument index, specifications, location plan drawing, instrument layouts, instrument hook ups, instrument wiring drawings prior to installation.
Accountable for the installation & configuration of instrument control systems, fire and gas systems, emergency shutdown systems and high integrity process protective systems.
Serving as Supervisor for efficient systematic construction of entire instrumentation work for inspection unit scope of works; attending technical meeting with Client Engineers.
Supervising construction activities such as cable laying, installation of junction boxes & marshalling panels, cable trays conduits, instrument stanchions, process variable field instruments, impulse tubing of instruments, pneumatic tubing of valves and termination of junction boxes and marshaling panels of DCS.
Performing calibration, loop checking, troubleshooting and functional test with cause & effect chart and control narratives.
Coordinating for pre-commissioning and start-up activities like instrument line up bypass, troubleshooting and online calibration of various process instruments along with Client Engineers & Vendors.
To prepare Quality Control procedures/ work instruction, ITP (Inspection Test Plans) according to project/ client requirements and follow-up for its approval and monitor the implementation.
Inspection of cable Trays and Cable laying installation for various types of instrument cables like core, pair, triad Shield and unshielded cables.
Ensuring the quality of the filed instruments, cables, junction box, tubing and piping are installed in accordance to client contract specifications.
Preparation of QA/QC dossiers and Test reports, lead, plan and participate with QA/QC Inspections, clearing of punch list.
Engaging in as-built instrument drawings as per field change and submission of the red lined drawing to the Engineering Department.
Procurement of material as per required specification and standard.
Preparation of weekly progress report and updating those to client.
Handling erection, installation, testing and commissioning of automation systems.
•Designing PLC based control systems which involves design & selection of Instrument control panel, detailed engineering on internal wiring of instrument control panels, PLC selection, SCADA configuration, execution & commissioning.
•Preparing IO's for the projects. Designing control panels and developing PLC Logic & SCADA.
•Commissioning and troubleshooting for the projects. Handling FAT inspection for the panels designed for the projects. Performing conceptual & detailed engineering and implementation of Automation & Control system. Reviewing hook up drawings.
•Executing process measurement & control instrumentation & services to optimize manufacturing processes.
•Developing logic, interlock diagrams as per requirement of process operation & client feedback.
•Assessing the arrangement diagram for control panel / PLC panel for commissioning of machine.
•Executing, configuring and testing of process specific interlocks; testing control panel logic and PLC logic.
•Undertaking design activities and detailed engineering of PLC/DCS systems, based on the client’s specifications and project requirements. Conducting Programming of PLC, SCADA, and HMI.
•Making as built drawings, Coordinating with clients’ for design approval, manufacturing, testing, erection and site commissioning.
Major Subjects: Material management, Maintenance management, Supply chain management, Quality Control management, Project management.
Bachelor of Engineering