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KARIM ABDALLAH, Maintenance Manager

KARIM ABDALLAH

Maintenance Manager·Steel Mill Services – Al Ezz Dekheila Steel Co. (EZ-DK)

Egypt

Master's degree, Engineering Management

Work experience

Total years of experience: 19 years, 9 months

Maintenance Manager

October 2013 - Present

Steel Mill Services – Al Ezz Dekheila Steel Co. (EZ-DK)

Alexandria, Egypt

October 2013 - Present

Promoted to lead expanded maintenance organization (since Jul 2017), managing section heads and scaling operations across heavy
equipment and fleet maintenance.
• Developed and executed maintenance strategy and asset lifecycle optimization, reducing total maintenance cost (OPEX) by 15%
improving equipment availability and utilization and cost efficiency across steel production, material handling, and operational
support environments.
• Managed maintenance planning, scheduling, and spare parts planning, work orders management, and backlog control using SAP
PM, integrated across cross-functional departments improving PM compliance by 20% and reducing maintenance backlog by 30%.
• Directed maintenance operations for heavy equipment and fleets including Caterpillar equipment, (KAMAG, KIROW) slag pot
carriers, (Mercedes, MAN, Volvo) heavy trucks ensuring high availability and operational continuity.
• Directed maintenance and reliability of crushing and material handling systems (crushers, screens, conveyors, rotary equipment),
maximizing equipment availability and ensuring stable production performance.
• Led troubleshooting, fault diagnosis, and overhaul of diesel engines, hydraulic, mechanical, electrical, PLC-controlled, and
rotating equipment (pumps, gearboxes, bearings), achieving an 80% in-house repair rate and improving maintenance efficiency.
• Managed cross-functional teams of 120+ personnel, driving TPM culture, autonomous maintenance, and workforce engagement,
while managing manpower planning, shift scheduling, and workorders management and execution.
• Implemented OEM-compliant preventive, predictive, and TPM-based maintenance programs, integrating condition monitoring
and reliability practices (RCM/RCA), improving equipment uptime by 15% and reducing unplanned downtime by 20-25%.
• Managed maintenance budgets, spare parts inventory, procurement, and OEMs/contractors, reducing costs by 15% and
improving inventory availability by 20% through effective vendor and contract management.
• Monitored and improved reliability KPIs (OEE, MTBF, MTTR, availability) through reliability improvement programs and failure
analysis, increasing MTBF by 15%, reducing MTTR by 20% and wrench time by 18% and strengthening workforce capability. Engineered asset life-extension projects KIROW slag pot exceeding OEM by reducing OPEX optimizing CAPEX utilization.

Company industry:
Heavy Industry & Metallurgy
Job role:
Maintenance, Repair, and Technician

Heavy Equipment Maintenance Senior Engineer

January 2013 - Present

Beshay Steel - Alexandria Sea Port

Alexandria, Egypt

January 2013 - Present

Led the maintenance and repair operations for SENNEBOGEN and LIEBHERR scrap handling cranes, overseeing hydraulic, electrical, and mechanical system diagnostics, repairs, and component overhauls.

Developed and implemented preventive maintenance strategies based on detailed equipment condition monitoring, effectively
reducing unscheduled downtime and enhancing crane efficiency.

Conducted and supervised quality maintenance operations, ensuring compliance with safety regulations and environmental standards to enhance operational efficiency and sustainability

Company industry:
Heavy Industry & Metallurgy
Job role:
Logistics and Transportation

Senior Heavy Equipment Maintenance Engineer

January 2013 - September 2013

Beshay Steel

Alexandria, Egypt

January 2013 - September 2013

Integrated Steel production company with port-based scrap and billet handling using cranes and heavy equipment.
• Led and guided operations of SENNEBOGEN and LIEBHERR material handling cranes for scrap and billet unloading from vessels,
ensuring safe and efficient port operations.
• Performed troubleshooting of hydraulic, electrical, and mechanical crane systems, heavy equipment and attachment tools.
• Ensured compliance with lifting operations safety standards, conducting inspections, functional checks, and safe maintenance
practices for crane operations.
• Supported material handling and yard operations, ensuring efficient scrap and billet flow from vessels to production lines,
improving operational continuity and equipment utilization.

Company industry:
Heavy Industry & Metallurgy
Job role:
Mechanical Engineering

Senior Maintenance Engineer

August 2010 - January 2013

Bahna Engineering International S.A.E

Alexandria, Egypt

August 2010 - January 2013

• Executed maintenance programs for slag pot carriers, steel mill Caterpillar loaders, and excavators used in hot slag and scrap handling,
sustaining 95% equipment availability and cutting unplanned downtime by 15%.
• Diagnosed and resolved complex failures in diesel engines, hydraulic circuits, and electrical systems, enhancing reliability by 20% in
high-temperature, heavy-duty operating conditions.
• Maintained and troubleshot Siemens S7 PLCs, HMI, and automation systems, ensuring 98% control system uptime and seamless
integration with production operations.
• Led equipment overhauls and system upgrades, extending asset service life by 3 years and reducing annual maintenance costs by 10%
• Optimized and Revamped spare parts inventory management, which improved inventory accuracy to 97% and directly contributed to
a 25% reduction in equipment repair times..

Company industry:
Mechanical Engineering
Job role:
Maintenance, Repair, and Technician

Senior Maintenance Engineer

August 2010 - January 2013

Bahna Engineering International

Alexandria, Egypt

August 2010 - January 2013

Steel Mill services provider supporting scrap handling, hot slag operations, and metal recovery (MR) plant systems.
• Maintained scrap handling equipment and fleet including TEREX Fuchs and Caterpillar excavators, loaders, heavy dump
trucks supporting continuous material handling operations.
• Directed maintenance and reliability of fixed plant equipment including conveyors, crushers, ball mills, and rotary drums,
ensuring continuous material handling, process stability, and high equipment availability.
• Coordinated shutdown maintenance and spare parts planning, improving maintenance response and reducing downtime.

Company industry:
General Engineering Consultancy
Job role:
Maintenance, Repair, and Technician

Senior Instrumentation & Automation Engineer

September 2006 - October 2010

RUBEX Company for Metal Industries |

Alexandria, Egypt

September 2006 - October 2010

Executed comprehensive preventive and corrective maintenance for industrial equipment, including DISAMATIC molding machines, induction motor, mixers, compressors, and induction furnaces to ensure optimal performance and minimal downtime.

Specialized in automation systems and field instrumentation, implementing advanced control strategies to enhance equipment
efficiency and reliability.

Company industry:
Heavy Industry & Metallurgy
Job role:
Manufacturing

Senior Maintenance Engineer

September 2006 - August 2010

RUBEX Company for Metal Industries (BE Group)

Alexandria, Egypt

September 2006 - August 2010

Steel manufacturing and foundry facility specializing in casting, molding, and automated production systems.
• Maintained automated steel processing and foundry systems, supporting continuous production of automated foundry
systems including DISAMATIC Machines, induction furnaces, material handling systems including Mixters, screens, conveyors,
and rotary equipment, ensuring high equipment availability and process stability
• Diagnosed faults in mechanical, electrical, and PLC-controlled automation systems, achieving 95% in-house repairs

Company industry:
Manufacturing
Job role:
Maintenance, Repair, and Technician

Education

Brooklyn Business School

November 2026

November 2026

Master's degree, Engineering Management

Egypt

Alexandria University

June 2006

June 2006

Bachelor's degree, Electrical And Electronics Engineering

Egypt

Skills

Maintenance
Expert
Maintenance
Expert
CMRP
Expert
CMRP
Expert
Electromechanics
Expert
Electromechanics
Expert
Fleet Management
Expert
Fleet Management
Expert
Heavy Equipment
Expert
Heavy Equipment
Expert
Hydraulic Systems Maintenance
Intermediate
Hydraulic Systems Maintenance
Intermediate
Team Leadership & Teamwork
Expert
Team Leadership & Teamwork
Expert
Problem Solving using Root Cause Analysis (RCA)
Intermediate
Problem Solving using Root Cause Analysis (RCA)
Intermediate
Fleet Management & Lifecycle Optimization
Expert
Fleet Management & Lifecycle Optimization
Expert
Budgeting and Cost Control
Intermediate
Budgeting and Cost Control
Intermediate
Management
Expert
Management
Expert
Project Management
Expert
Project Management
Expert
Installation
Expert
Installation
Expert
Maintenance Management
Expert
Maintenance Management
Expert
PLC , HMI (Siemens) and Automation System
Expert
PLC , HMI (Siemens) and Automation System
Expert
Inventory Management and Spare parts control
Expert
Inventory Management and Spare parts control
Expert
SAP Plant Maintenance (SAP PM) & CMMS
Expert
SAP Plant Maintenance (SAP PM) & CMMS
Expert
Heavy Equipment Maintenance and Repair
Expert
Heavy Equipment Maintenance and Repair
Expert
Preventive & Predictive Maintenance (PPM)
Expert
Preventive & Predictive Maintenance (PPM)
Expert
CAT SIS & ET & Star Tool
Expert
CAT SIS & ET & Star Tool
Expert
Data Analysis & Visualization
Intermediate
Data Analysis & Visualization
Intermediate
Power BI, Minitab, MS Project
Expert
Power BI, Minitab, MS Project
Expert
CERTIFIED PLANT MAINTENANCE MANAGER
Intermediate
CERTIFIED PLANT MAINTENANCE MANAGER
Intermediate
ASSET MANAGEMENT
Intermediate
ASSET MANAGEMENT
Intermediate
COMPUTER HARDWARE
Intermediate
COMPUTER HARDWARE
Intermediate
CONTINUOUS AVAILABILITY
Intermediate
CONTINUOUS AVAILABILITY
Intermediate
FACILITY MANAGEMENT
Intermediate
FACILITY MANAGEMENT
Intermediate
FLEET MANAGEMENT
Intermediate
FLEET MANAGEMENT
Intermediate
OPERATIONS
Intermediate
OPERATIONS
Intermediate
PREVENTIVE MAINTENANCE
Intermediate
PREVENTIVE MAINTENANCE
Intermediate
TRUSTED PLATFORM MODULE
Intermediate
TRUSTED PLATFORM MODULE
Intermediate
WEB PERFORMANCE OPTIMIZATION
Intermediate
WEB PERFORMANCE OPTIMIZATION
Intermediate

Languages

English
Expert
Arabic
Native Speaker

Memberships

Society of maintenance and reliability professionals

Maintenance and Reliability professionals

January 2024

Training and Certifications

Certifications
Project Management Professional (PMP)
Reliability-Centered Maintenance (RCM)
Maintenance & Reliability KPIs (SMRP Approved)
Financial & Cost Management for Maintenance & Asset Management
Caterpillar Advanced Hydraulic & Transmission Systems – Mantrac (CAT Dealer)
Six Sigma Green Belt (Lean & 5S)
Certified Asset Management Assessor (CAMA2) ISO 55001 aligned
Certified Maintenance & Reliability Professional (CMRP)
Certified Asset Management Assessor CAMA2
RES Global
Nov 2025
Certifed Maintenance and Reliability Professional (CMRP)
Feb 2025 - Feb 2028
Show credentials

Training
Financial & Cost Management for Maintenance & Asset Management
RES Global (SMRP Approved Provider)
Jan 2025
Show credentials
Maintenance & Reliability KPIs
RES Global (SMRP Approved Provider)
Mar 2020
Show credentials
Reliability Centered Maintenance (RCM)
RES Global (SMRP Approved Provider)
May 2018
Show credentials

Hobbies

  • Data Analytics