Senior Reliability Engineer and eAM Advisor
MAADEN
Total years of experience :17 years, 10 Months
For Reliability Engineering:
- Participates in the development of design and installation specifications along with commissioning plans. Participates in the development of criteria for and evaluation of equipment and technical MRO suppliers and technical maintenance service providers. Develops acceptance tests and inspection criteria. (Mostly done in Pre commissioning phase for Maaden Refinery, end of 2014)
- Participates in the final check out of new installations. This includes factory and site acceptance testing that will assure adherence to functional specifications.
- Guides efforts to ensure reliability and maintainability of equipment, processes, utilities, facilities, controls, and safety/security systems. (Tracked Via ALCOA special tool “REX” - Reliability Excellence, The Australian Standard)
- Professionally and systematically defines, designs, develops, monitors and refines an Asset Maintenance Plan that includes both Value-added preventive maintenance tasks along with Effective utilization of predictive and other non-destructive testing methodologies designed to identify and isolate inherent reliability problems.
- Develops engineering solutions to repetitive failures and all other problems that adversely affect plant operations. These problems include capacity, quality, cost or regulatory compliance issues
- Generate Data analysis techniques that can include:
- Statistical Process Control
- Reliability modeling and prediction
- Fault Tree and event tree Analysis
- Weibull Tree Analysis
- Root-cause and Root-Cause Failure Analysis (RCA, RCFA)
- Failure Reporting, Analysis and Corrective Action System
- Periodic standard KPI’s reports
For eAM Supervision:
- Led the eAM implementation team (Six eAM specialists from three multinational companies) through the implementation phase until the Go Live.
- Created asset hierarchy, asset register and complete technical data gathering for capital assets
- Helped in design of customized work flow of the eAM for Maintenance and Procurement Modules
- Completed failure codes library through specialized workshop
- Supervised system upload activities for Assets, Maintenance Activities, PM’s, BOM’s, Departments, Resources along with all required associations.
- Participated in customizing eAM reports for maintenance and procurement.
- Currently Administrating all eAM activities, reports and integration projects with other systems.
Projects and operations
Generate project plans for new constructions and/or revamps for both field managers and working contractors
Manage projects with detailed WBS’s (level three and four) schedules to direct the involved planners and executers
Co-ordinate with operation engineers to maintain the quality of plans carried out in their areas and provide them with relevant schedules and project controls
Establish and operate project controls and release different reports and KPI’s
Maintenance
Construct and/or redesign long term maintenance and inspection plans (preventive and predictive) including all relevant details (Job plans, man power, material, and budget)
Follow up and monitor maintenance and inspection activities in site and over the CMMS (MAXIMO).
Plan and prepare for corrective maintenance activities and lead maintenance teams during execution period
Release maintenance work orders and follow up their relevant work flow over the CMMS (MAXIMO)
Monitor the outstanding work requests, work orders and due / overdue Inspection and maintenance items in System Backlog
Ensure that stocks of spare parts are strictly monitored and kept at optimum levels
Monitor maintenance costs and make recommendations for improvement
Develop different performance measurements and KPI’s to improve maintenance quality and efficiency
Report progress of maintenance activities and projects via routine or customized reports (Weekly, Monthly, Quarter, Annual and on demand reports)
Maintain a close follow up of Monthly maintenance activities, report deviations from the programme and propose alternatives
Develop and maintain the quality of the CMMS by applying necessary changes and upgrades
Reliability
Prepare & provide plant availability & reliability data on regular basis
Implement different maintenance methodologies and strategies using FMEA sheets to select the best practice plans according to business requirement
Keep and analyze equipment failure data records and history
Assure the continuous improvement of RCM and all relevant integrations
Plan and develop strategies for measures to reduce down time for working assets
Participate in RCA investigation teams
Monitor all actions identified on the reliability & compliance registers to ensure satisfactory closeout, including maintaining close out records & storage of historical recording progress on all reliability related engineering jobs
Coordinate all activities related to the ongoing completion and update all identified reliability improvement Plans
Ensure compliance with national (Egyptian) & International standards and HSEQ procedures and practices in design, engineering and maintenance in oil and gas industry
Shutdowns
Co-ordinate with different maintenance and operation departments to construct shutdown scope of work and prepare the required work list
Generate shutdown master schedules and develop integrated shutdown plan on different levels with the required material and labors
Prepare shutdown work packs for all maintenance and inspection activities (divided by equipment)
Ensure that shutdown work scope is fully defined and plan-able
Ensure that shutdown schedules are well prepared and have the right time frames (not overinflated)
Facilitate contractors kickoff meetings and provide them with sufficient data
Follow up maintenance and inspection activities during shutdown times, report daily progress (actual vs. planned, S-curve, overall trends and shutdown summary)
Issue shutdown closeout reports and KPI’s
General tasks
Co-ordinate with different maintenance and operation departments through number of meetings (daily operation meeting, maintenance bi-weekly meeting and shutdown meetings)
Give frequent presentations to maintenance and operation personnel
Participate in CMMS upgrades and new implementation projects
Day shift Maintenance Engineer.
Asset Management Diploma in the AUC (2012)
Business Communication Diploma (Five staged Diploma in AMIDEAST, 2008) 1. Business reading & writing. 2. Business meetings and negotiations. 3. Business marketing and advertising. 4. Presentation skills. 5. Soft skills
B.Sc. of Industrial Engineering, Alexandria University, 2007 Graduation project: Asset Management and Resource Planning, Grade, Distinction