General Manager – Research and Development , NIPRAS
TASNEE Petrochemicals
Total years of experience :26 years, 6 Months
Tasnee is the second largest producer of petrochemical products in Saudi Arabia. http://www.tasnee.com/
Designation Chronologyu**
• Jan 2014 - to date, General Manager, Research and Development, NIPRAS
• May 2011 - Dec 2013, Polymer Process Engineering and Quality Assurance Manager
• Jul 2009 - May 2011, Polyethylene Operation Manager
• Apr 2008 - Jul 2009, HDPE Superintendent
About NIPRAS u**
• National Industrialization Product Research Applications and Support Centre (NIPRAS) supports the company’s regional and global market growth through product innovation, product design and development.
Highlightsu**
• Improved processes and enhanced alignment of marketing, technical and recruiting teams with customers.
• Successfully completed and handed over to the market team 4 projects.
• Significantly increased the range and scale of training services offered including training of new Saudi engineers.
• Implemented the company’s Integrated Management Rating System (IMRS) in NIPRAS to standardize processes. Won the award for the best implementation of IMRS in the 2nd phase.
Key Responsibilitiesu**
• Manage operations of NIPRAS assuring achievement of all Balanced Scorecard (BSC) objectives aligned to corporate goals and objectives.
• Formulate and implement strategies and plans to achieve all functional objectives of the Centre.
• Provide required support in process improvements and product development to the complex operations of the company to maintain its leadership position in the market.
• Develop and sustain partnerships with leading process licensors, Saudi universities and local and global research houses in executing joint applied research programs.
• Collaborate with clients and customers in order to analyze their requirements and problems to provide cost effective and viable technical solutions.
• Participate in identifying potential new business opportunities and conducting technical feasibility studies.
• Monitor and assure adherence to all requirements of the company’s quality, safety, health and environment policy and procedures.
Highlightsu**
• Both Process Engineering and Quality Assurance departments achieved highest score in IMRS implementation in the 1st phase.
• Increased the capacity of Line 2 by modifying the rotary feeders which improved average load capacity by 1.5 T/hr with annual financial benefits of USD 1.06 million.
• Reduced catalyst loading by 13% and incremental loading by 4.5% by installing a CO-bed leading to high on-stream capacity with total financial benefit of USD 3.8 million per year.
• Improved monomer ratio with significant saving in propylene amounting to USD 7.1 million per year.
• Identified bad actors in the extrusion process and resolved several issues during TAM 2013. Improved on-stream factor for Line 2 from 93% to 96% and sustained on-stream factor of Line 1 at 94% with higher capacity after replacement of discharge vessel.
• Reduced lumps formation in R1202 by completing hot boiling activities with help of LYB.
• Reduced auto polymerization in the hyper compressor by commissioning a technical air injection system.
Key Responsibilitiesu**
• Coordinated process control and quality assurance activities of all polymer lines to improve performance in the areas of safety, quality and environment aligned to departmental objectives.
• Studied current processes and implemented viable modification projects leading to significant process efficiency and cost benefits.
• Conducted benchmarking studies of polymer units, mapped gaps with predefined standards and recommended remedial action plans.
• Evaluated all management of change (MOC) proposals submitted by process owners assuring completion within an average of 2 weeks.
• Led the culture enhancement team and the reward and recognition team to improve people management and employee engagement.
• Evaluated LYB catalysts for the second phase and led the development and review of LYB catalyst agreements.
• Implemented a new procedure for organizing product quality meetings (PQM).
Highlightsu**
• Set up teams to identify bad actors and implement corrective measures improving reliability and availability of HDPE and LDPE plants.
• Implemented an improvement program which reduced the number of shutdowns of the nitro-dryer from 6 times to 2 times per year.
• Improved awareness of and compliance with safety concepts by organizing special safety sessions at shift level.
Key Responsibilitiesu**
• Directed and controlled operations of LDPE and HDPE plants assuring safe operations and on time, on-spec delivery of products within approved costs.
• Implemented various programs to achieve continual improvements in plant operating efficiency, safety, process integrity and plant reliability.
• Supervised all activities related to people management including motivation, training and performance evaluation to improve productivity of the workforce.
• Monitored utilization of raw materials, consumables and catalysts and ensured adherence to company’s standard norms.
• Enforced all rules and regulations related to safety, health and environment across all units.
• Monitored and ensure achievement of all KPI targets aligned to overall company goals and objectives.
Highlightsu**
• Contributed to the successful start-up of the HDPE plant in Nov 2008
• Participated in obtaining certifications to ISO 9001, ISO 14001 and OSHAS 18001 standards within six months of plant start-up.
• Developed a team of qualified field and panel operators with the support of the LYB start-up team.
• Replaced heat exchangers and reduced average shutdown period of nitro-dryers from 6 days to 4 days.
Key Responsibilitiesu**
• Managed all plant activities for manufacturing various grades of dry superabsorbent polymers (SAP) ensuring high quality, on time on-spec production within approved costs.
• Coordinated and led studies to identify opportunities and implement programs for improving performance on parameters of safety, operational efficiency and quality.
• Integrated technical and non-technical aspects of production processes and equipment to optimize plant performance.
• Dealt with people management aspects including training, development, performance evaluation and employee engagement.
• Developed and implemented standard operating procedures (SOP) for all key operational activities.
• Developed departmental budgets, monitored costs and led cost saving and cost reduction programs.
• Followed up and ensured compliance with all company strategic plans, policies and procedures.
• Enforced all requirements of safety, health and environmental management systems in the unit.
SABIC is one of the largest industrial organizations in KSA. SHARQ, a SABIC affiliate is a major manufacturer of a wide range of petrochemical products.
Designation Chronologyu**
• Oct 2003 - Mar 2008, Superintendent, Polymer Section
• Nov 2001 - Oct 2003, FANAR Project - Production Planning Module Power User
• Jun 2001 - Oct 2001, Superintendent, Polymer Section
• Sep 2000 - May 2001, Process Engineer, Polymer Section
• May 1998 - Aug 2000, Project Engineer, 2nd PE Expansion
• Oct 1997 - Apr 1998, Engineer, PE Operations
Key Projects to Credit u**
• FANAR Project - The project was aimed at SABIC global business transformation by implementing a pre-configured SAP package incorporating good business practices in the chemical industry to strengthen SABIC’s competitiveness. - Worked as Power User for the Production Planning Module in SHARQ.
• 2nd Polyethylene Expansion Project - Contributed to safe commissioning and start-up of the extrusion and conveying systems with no major incidents.
Highlightsu**
• Implemented programs which improved overall performance and utilization of extrusion lines.
• Optimized the consumption of steam and nitrogen and reduced production costs.
Key Responsibilities as Superintendent, Polymer Section u**
• Supervised, directed, monitored and controlled plant activities for production of superabsorbent polymers (SAP). Ensured adherence to SOPs and QMS requirements to deliver high quality, on time, on-spec products within approved costs.
• Focused on people management initiatives to develop competent staff, supervisors and operators.
• Organized and led a team for conducting benchmarking studies of plant operations and processes and identify opportunities for improvement.
• Supported the establishment of business processes in the company and developed required SOPs.
• Coordinated the integration of technical and non-technical aspects of production process.
• Identified areas of concern related to safety, reliability, operational efficiency and quality in plant and processes and implemented corrective action plans.
• Prepared budgets and ensured compliance with approved budgetary limits.
• Monitored plant performance and prepared periodic KPI achievement reports.
Key Responsibilities with FANAR Projectu**
• Implemented the Production Planning Module in all departments of the company.
• Coordinated end-user training and post rollout support for smooth implementation of SAP.
• Participated in full implementation and integration with other modules of SAP.
• Reviewed and updated all procedures to derive the full benefits of SAP implementation and integration.
Key Responsibilities with Process Engineeru**
• Evaluated and recommended action on several ideas for process improvements.
• Supported the plant in reducing power consumption by optimizing the utilization of existing interchangeable conveying system.
• Implemented a program to calculate monthly production costs excluding maintenance costs and overhead costs.
Key Responsibilities as Project Engineer, 2nd PE Expansionu**
• Reviewed engineering drawings of the extrusion and conveying systems and overall utilities of the plant.
• Coordinated with the project and construction teams in commissioning and start-up of the units.
Key Responsibilities as Engineer, PE Operations u**
• Joined the operations team of the polyethylene plant as a fresh engineer and underwent on-the-job rotational training to gain familiarity with various processes of the plant.
• Recognized for fast learning by transfer to the team for the 2nd PE expansion project.
Bachelor’s Degree in Chemical Engineering Graduation Project: Production of Urea at the existing plant of SABIC. Designed the reactor for the process, running the model on FORTRAN Project Grade: A+ Professional Development Trainings • Management Skills, Negotiation Skills, Effective Communication Skills • Mini MBA, Strategic Thinking, Conflict Management • Finance for non-Finance People • System development, Systematic Working and avoiding Fire Fighting • Motivating People, Influencing without using Authority, Awareness of the impact of own behaviour on others Certifications • Certification from Centre for Creative Leadership (CCL), Dec 2011 • Microsoft Certified Engineer (MCE), Jan 2007 • Certification from Chiyoda, Japan, Jan 2003
