KARIM ABDALLAH

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.

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

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.

• 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..

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.

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.

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