Production Manager
Oilfields Supply Company Saudi
مجموع سنوات الخبرة :25 years, 4 أشهر
Joined OSC Saudi when it just moved to a new location with undeveloped infrastructure, lack of manpower and resources as well as many new machinery and equipment that was yet to be installed and commissioned. COVID impact prevented OEM’s visiting the plant and therefore lot of coordination had to be done online with limited resources to finalize installation / commissioning and develop operational procedures and preventive maintenance planning. I had a chance to review, modify and improve manufacturing process flow, prepare operational documentation and processes for ERP launch, improve time keeping process and thus cutting costs, vitalize preventive maintenance systems, help our Supply Chain, HSE and Facilities teams to provide more efficient and better service to our operations. Was heavily involved in proposal and estimation stage, helping our sales to correctly estimate cost of manpower, consumables, and equipment (if any) required for the job. To summarize:
• Setting up and running manufacturing shops for heat exchanger, skids, and other equipment
• Shops included: Cutting, Rolling, Welding, Machining, Blasting & Coating facilities as well as stores.
• Other operations: Mn-Phosphating, Nickel Sulphate & Chrome Plating (for drilling tools service)
• Implementing Lean Management on the shop floor
• Assisting Engineering and Quality teams on matters of welding and mechanical engineering
• Managing resources, teams, machinery maintenance and etc.
• Helped to obtain Aramco approvals for various 9com’s including process internals, pressure vessels (thicker than 19mm) and etc.
• Assisting Estimations team in providing manhours and cost estimation for bids
After many years being away from Caspian and BP related projects, I was back here again leading a team of quality professionals at a jacket and subsea fabrication projects. Formally, I was BP Quality representative on Jacket and Subsea manufacturing and erection at Contractor premises. Our team was overseeing more than 20-person strong subcontractor quality team and all related fabrication activities in this enormous Soviet era-built manufacturing entity called Deep Water Jackets Factory. Manufacturing process involved receipt, storage, sweep blasting of free issue steel (including more than 140mm steels), cutting as per nesting sheets, rolling, welding, coating, assembling, testing and erection on site.
Besides this massive Jacket weighing: 16500 ton and 153 meters long we were also covering subsea fabrication and repair work for CGLP and SD2 projects (repair job). Our scope here also included FBE or PTFE coating for subsea operations.
I was responsible for implementing the project Quality Management System in conformance with BP quality management processes and for managing Quality Control activities across full spector of contractor and subcontractor activities; authoring and maintaining applicable project quality documents required to execute the quality activities; managing BP quality team personnel within the project; providing guidance, advice and training to project team, contractors, suppliers, inspectors and third parties as required to confirm understanding of the project Quality objectives; identifying risks in the contractors and sub-contractors performance or project overall and together with the management team identify best mitigations; capturing lessons learned future projects and recommending related process improvements (via shared Learning System); analysing trend data, KPI’s from the contractor for improvement processes.
Having experience of working for Aramco is a great achievement for me personally and it added a great deal to my management and process improvement skills. Be it investigating failures reported from site with the OEMs in Europe or performing management system assessments in our approved EU supplier plants, I greatly benefited from it all. Aramco contributed a great deal to my professional development but the situation with parents made me quit this job in The Netherlands and go back to my first home, Azerbaijan. I had opportunity to learn from best manufacturers in Europe when Evaluating their production capabilities and management systems and helping them to achieve significant process improvements. By performing Root Cause Analysis of failures reported from site involving when necessary, failure mode assessments, lab analysis and focused process audits at manufacturing locations, we could always get to the actual direct cause and find best improvement action possible to avoid repetition. I also was contributing to Lessons Learned system of Aramco and did several Agency Inspector tests and examinations for employed Inspection Agencies.
Achievements & Training:
• Metallography & Microscopy course from Sheffield University
• Failure Analysis & Prevention course from Sheffield University
• CSWIP 3.1 Welding Inspector - 10 year renewal exams successfully passed
• Introduction to Lean Thinking course taken, exams passed
• Cutting and Welding 2017 Expo, Dusseldorf, Germany - Scouted specific technology for Aramco
• White paper "Challenges of Welding Catalyst Tubes in Hydrogen Reformers" published and presented in Materials Performance & Welding Technology Conf. 2017 in Dammam, KSA (org. by AWS /NACE).
• White paper "Relaxation cracking in austenitic stainless steels (Hydrogen Reformer failures case study)" published and presented in MECC 2018 in Bahrain (AWS/NACE event)
• Fabrication Math 2 Seminar taken, exams passed
• NACE L2 Coating Inspector training.
• Became member of AWS (Am. Welding Society) and extended membership in DVS (Germ. Welding Union)
• Scouting for developments in welding technology and sharing them within organization
• Systemized EDR (Equipment Deficiency Report) handling process, developed flow chart and procedure
• Achieved several process improvements and manufacturers as a result of Root Cause Investigations.
• ISO 9001:2015 Lead Auditor certificate from BSI
Throughout my 8-year tenure with Technip Netherlands, I have been involved in various roles in Construction and Manufacturer Management. My focus in manufacturer management was to ensure that equipment manufactured for Technip's projects worldwide was made according to best technology and standards available as well as on time and within project budget. The Netherlands branch of Technip (Technip Benelux) was focused on ethylene cracking and hydrogen production units, this gave me an opportunity to gain deeper knowledge into processing, piping and mechanical engineering behind this equipment. I was helping our manufacturing partners to develop better processes, schedules, reviewing their welding, engineering, and quality documents, participating with our engineering in tender bid technical reviews, contract reviews, HAZOP studies for projects as well as other engineering and project management functions. Reporting functionally directly to project manager, I was often visiting Technip’s vendors and construction sites for supplier qualification, welding engineering, expediting or quality management roles
Once I moved into Construction department, I had the opportunity to develop construction schedules, planning, job cards and method statements as well as physically manage or supervise construction on Technip's sites worldwide.
Various roles with EPCs such as McDermott, Saipem and others. Geographies included Caspian Sea, Georgia and Saudi Arabia
Projects: Kursangi, Karabagli, Kirovdag onshore oil field development:
Tanks Construction & Repair to API 650
Pipeline (crude, gas, water) Construction, Replacement & Repair
Crude Processing Laboratory Upgrade
GPS project Facilities Mapping
Water Disposal and Re-injection Projects
• Control of Tank and Pipeline construction activities as per standards, contract specs and drawings
• Set up and commissioning of instrumentation of Mobile Water Knock-Out metering unit.
• Procurement and Warehouse operation control
• Materials Specifications and on receipt quality inspection
• Material Handling and Control Activities
• Equipment Database
• Various technical tasks
• Technical Interpretation and MOM
Achievements / Experience:
• Introduction to Welding, Mechanical Erection, Construction and Quality Control in these fields
• Familiarization with GOST, SNIP, ASME, ASTM and other Oil Industry related Construction practices
• Application of API 650 for Oil storage tank constructions
• Familiarization with Oil field equipment, materials and technology
• Working in remote locations on permanent terms
• Training providing and self development skills
• Organization skills, brainstorming sessions, “lessons learned” skills
• “MAPINFO” software training for GPS project application
• ACCESS database familiarization - “RISK” group training Baku, Azerbaijan
• Degree Welding Engineer (IWE diploma) – GSI SLV, Duisburg Germany • Studied: Welding processes and Equipment, Metallurgy of Welding, Construction and Design of Welded Structures and Equipment, Fabrication and Application engineering
• Degree: Bachelor of Science; University: Az. State Univ. of Oil and Industry (Baku, Azerbaijan) • Faculty: Production Process Automation • Minor: Remote Sensing in Space Research, Geodesy; • Studied: Physics, Calculus, Space Research, Ultrasonic wave properties and application in remote sensing, Industrial Process Measurements, General Drafting and etc.
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