Operation and Maintenance Head
UNIGRAIN, Affiliate of Samtrade Unifert Misr, Samir Fahmy Group.
Total years of experience :31 years, 0 Months
Loading and unloading of grain and general cargo with storage capacity of 500, 000 tons.
Reported to: Chairman of the Board and Managing Director.
RESPONSIBILITIES:
• Heading two major divisions within Engineering department (Operations and Maintenance) with team of 200 members, Engineers, Technicians, Drivers and Operators overseeing their activities.
• Overseeing day-to-day management of maintenance and operation workload, coordinating with operation manager for loading and unloading tasks, and collaborating with maintenance manager for maintenance work.
• Manage a fleet of Actros, Volvo, Iveco and MAN trucks to transport grain from the ship to the warehouses, Drivers, spare parts, preventive maintenance and corrective maintenance to ensure effective ships unloading performance.
• Manage a fleet of Mercedes, Chevrolet and Toyota buses for employee’s transportation.
• Manage 20 Caterpillar Loaders operation and maintenance to load grain from warehouses to customers.
• Manage 8 Caterpillar Skid Steer Loaders for services.
• Manage 6 Caterpillar Gensets 500KW and 1MW.
• Manage 3 Huge bucket elevators for automated warehouses.
• Manage 4 Ship Unloaders VIGAN with capacity of 2000 Ton/h.
• Manage 20 mobile loading belt conveyor for grain.
• Manage store spare parts and stock level for all equipment.
• Coordinates, monitors and performs preventive, predictive and proactive maintenance and repairs of company’s facilities and utilities, ensures all are well maintained and safe at all times through preventative maintenance and repair work on a variety of buildings, including multiple fire stations, power stations, compressed air lines, an administrative facility, an equipment maintenance facility, fuel station, ventilation system, lighting towers, HVAC systems, electrical systems, power generators, exhaust systems, irrigation systems, bay door operations systems and building structures including roofs, gutters, doors, drywall, flooring and painting and all 13 warehouses buildings.
• Evaluating project requirements to identify and mitigate risks.
• Managing design and manufacturing teams to build proprietary process equipment within aggressive cost and time constraints.
• Developing and implementing strategies to enhance operational efficiency and reduce costs.
• Establishing and nurturing strong relationships with customers and suppliers to facilitate timely delivery of materials and services.
• Supervising employee performance, preventive maintenance, and safety.
• Preparing and reviewing maintenance contracts with external service providers to offer mutually binding agreements.
ACHIEVEMENTS:
• Increase the total grain storage capacity by 70, 000 Ton by buildup huge steel structure warehouse 9000 m2.
• Refurbish, modify and upgrade the ship unloader #1 after destroyed fire accident with local team.
• Proven cost saving more than 8 million EGP in different sections detailed report ready upon needed.
• Due to the cone shape of grain inside warehouses we waste about 35% of total warehouses space when store two different type of grain to avoid the mixing, and the waste is increase too much when store more than two types. So, I started to use the mobile concrete wall for first time to make separations inside the warehouses and reduce the waste to the minimums level and increase total company storage capacity by use all empty areas.
Oil and Gas Field (American Petroleum Institute API Spiral Steel Pipe Manufacturer) Approved by Saudi ARAMCO.
Reported to: CEO.
RESPONSIBILITIES:
• Headed 6 major sections under Engineering and Maintenance department with an employee strength of 150 members and oversaw.
1 - Automation (PLC - Control - Instrumentation - Electrical - Electronic)
2 - Mechanical (General Mechanics - Valves - Heavy Equipment - Cranes - Scaffold - Manlift - Air Compressors/Dryers)
3 - Hydraulic (Hydraulic System - Pneumatic System)
4 - Engineering (Fabrication - Design)
5 - Machine shop (Fabrication - Design)
6 - Facilities (Plant Facilities and Utilities MEP)
• Overseeing the day-to-day management of the Maintenance workload and execution tasks, implementing Preventive Maintenance Programs (PM) for all plant critical equipment.
• Working closely with the Engineering teams and collaboratively with the production manager & QC Manager for maintenance of equipment associated with production /QC
• Promoting a positive culture that focuses on continuous improvement & operational excellence by analyzing trends, evaluating maintenance department procedures and action plans to achieve the desired goals.
• Continuously striving to improve the condition and performance of equipment, while ensuring it can be operated safely and effectively.
• Coordinating tasks and resources within the maintenance department, implementing maintenance strategies to support daily and weekly schedules in addition to ascertaining availability of spare parts for all critical equipment prior to breakdowns.
• Ensuring that maintenance staff is adequately trained on electrical, electronic, automation control and PLC and completely equipped, so that the maintenance program can be accomplished in a safe, timely, and cost-effective manner.
• Reporting directly to CEO, participating in management review meeting and attending all management meetings necessary to monitor and manage the project, chairing as appropriate
• Playing an instrumental role in ensuring adherence to ISO 9001:2008 & API Standard, ascertaining all contract documents are in order and ensuring conformance to established budget and project milestones in conjunction with Project Lead.
• Determining the proper priority of all maintenance activities, maintaining appropriate schedules, assign scope of work to subcontracts and document all contract riders and purchase orders in conformance with project insurance requirements
• Provided technical leadership, support and expertise for purchase and delivery schedules, change order processes, shop drawings, document control logs, Architect and Subcontractor correspondence, etc.
• Making several cross-border visits to France, Germany, Austria, India, China, Bahrain, Emirates, Turkey
ACHIEVEMENTS:
• Played a key role in training electrical team on electrical and electronic systems, automation control and PLC (both in English & Arabic).
• Significantly contributed in establishing one of biggest Pipe Manufacturing Mill Plant in middle east based on Offline welding process technique to produce Spiral welded pipe from Carbon steel hot rolled coil material meet the requirement of API Standard as well as handled all technical discussion with leading organizations including Schuler, Linsinger, Demag, Lincoln and Urhan & Schwill.
• Due to the high thickness pipe line of new project for Saudi ARAMCO it was required to upgrade all production line #3 to win the big deal and we did it with our local team.
Member of HPH group Hutchison Port Holdings which operations are spread across 58 Terminals in 27 Countries including 2 Terminals in Egypt (Dekhela port & Alexandria port).
Loading and unloading containers.
Reported to: COO.
RESPONSIBILITIES:
• Performed repairs and maintenance to extend working life of installed machinery & equipment and ensured safety, minimized breakdown and maximized productivity.
• Handled day-to-day activities of the department by extending knowledge of all container terminal equipment including quay cranes - STS ship to shore, RTG rubber tire gantry, BROMMA Spreader, mobile crane, overhead crane, reach stacker, empty container handler, fork lift, truck and trailer, generator, LV & MV power station, switchgear, MV transformer, circuit breaker, firefighting system, UPS - power supply unit, gearbox, inverters, PLC, refrigerator container, lighting tower, ventilation and AC system and many more.
• Maintained effective communication and coordination with Operation & Planning & purchasing, QC & Logistic, Safety & Security & IT departments for ensuring that the maintenance activities are carried out in the most efficient and cost-effective manner.
• Provided technical leadership to Electrical & Mechanical technicians and trained them for new work methods, changes in regulations, work policies and organizational standards to ensure efficiency, maximize output and prevent downtime.
• Generated an array of technical reports (Work done & Fueling sheet & Equipment status & accident investigation report & vessel report & Spare parts & fault sheet), conducting RCA for non-conformances, break down, deviations & undertaking remedial measures to avoid bottle-necks.
• Used ERP - Oracle systems to support the technical programs through on-going maintenance systems, robust maintenance strategies and scheduled repairs & preventive maintenance activities
• Mediated with vessel staff in case of accident or damage on vessel and provided prompt maintenance and repair services. Carried out and reviewed monthly audit of all equipment.
ACHIEVEMENTS:
• Recorded success in three major areas, including Repair, Modification, and Innovations and Inventions.
• Managed to repair all previously replaced defective parts, encompassing Power supplies, Equipment joysticks, PLC Modules & Power supplies, Warning devices, Beacons, Pressure sensors, Control cards & firing cards.
• Implemented several innovations and modifications, such as the Intercom test panel, installation of a microphone in RTGs, installation of a camera system in RTGs, installation of ZPMC Joystick on Sumitomo RTGs, and modification of the motor brake circuit
• Invented several new techniques that were successfully utilized, including lighting towers controlled by phone call, a new power supply, reach stacker spreader control card PCB test panel, and reach stacker spreader control card PCB and Encoder tester
Design and repair of industrial electronic cards and home appliances.
Reported to: Maintenance Manager.
RESPONSIBILITIES:
• Maintenance of all types of home appliances Such as air conditioning, refrigerators, washing machines, ovens, microwaves, kitchen appliances, irons, fans, televisions, receiver, audio devices, and mobile phones,
• Coordinating with home appliance agencies to learn about all the latest maintenance tips, troubleshooting, software, and providing spare parts.
• Attending periodic training for maintenance agencies to learn about the latest developments, transfer them, and train technicians on them
• Provide technical support in the workshop, on call, or if necessary, for a home visit to maintenance team.
• Writing reports on devices and malfunctions and creating files for clients.
• Preparing an updated list of spare parts and maintenance tools and managing inventory of the spare parts store.
• Preparing a list of unavailable spare parts and finding suitable alternatives for them.
• Managing an entire department for purchasing, repairing, refurbishment old devices and reselling them.
• Study and explain electronic diagrams of devices to technicians to clarify fault detection.
• Delivered expertise in operations, maintenance, design & repair of industrial electronic cards, medical devices, variable frequency drives (VFDs), PLC Modules and power supply units.
• Scheduled and planned preventive and breakdown maintenance for improving overall reliability and safety.
• Oversaw the servicing, maintaining and repairing of breakdown equipment, diagnosed breakdown problems and prepared the technical reports of breakdowns to avoid further recurrence and improve productivity.
Operation and Maintenance Department (O&M).
Reported to: Maintenance Manager.
RESPONSIBILITIES:
• Proved successful working within tight deadlines and fast-paced environment.
• Trained and mentored personnel in combat operations and tactics.
• Planned and coordinated tactical movements of personnel and equipment.
• Analyzed intelligence reports and identified potential tactical threats.
• Coordinated activities of subordinate personnel to support mission success.
• Prepared and delivered investigative reports and briefings.
• Repair Power supply units.
• Calibration of measurement instruments.
• Repair Fermentation ovens.
• Repair electronic cards
Maintain and repair all types of industrial equipment.
Reported to: Maintenance Engineer.
RESPONSIBILITIES:
• Install, maintain, and repair electrical wiring, fixtures, and equipment according to electrical codes and safety regulations.
• Troubleshoot and diagnose electrical problems using test equipment and technical knowledge.
• Perform preventive maintenance tasks on electrical equipment to prevent breakdowns and extend its lifespan.
• Repair and replace defective electrical components, such as switches, outlets, circuit breakers, and motors.
• Install and maintain lighting systems, including fluorescent, LED, and high-intensity discharge (HID) lamps.
• Install and maintain electrical control systems, including programmable logic controllers (PLCs) and variable frequency drives (VFDs).
• Conduct electrical safety inspections and tests to identify potential hazards and ensure compliance with safety regulations.
• Prepare and maintain accurate records of all electrical work performed.
• Follow all safety procedures and wear appropriate personal protective equipment (PPE).
• Assist other maintenance technicians with electrical tasks as needed.
Menoufia University, Faculty of Electronic Engineering, Munuf, Egypt. 2000, Bachelor degree, Electronic Engineering, Automation control systems and measurements.