خليل مشعل

• Leadership: lead the Electrical Department supporting 5 production lines and 14 overhead cranes; manage
teams of 6-14 engineers and technicians across six major shutdowns, turnarounds, and commissioning
projects.
• Digital transformation: Designed and led development of a custom Enterprise CMMS integrating
maintenance, production, HR, inventory, KPI reporting, and machine monitoring — now supporting 38
managed assets.
• Industrial IoT: installed a SCADA workstation and built cloud-based logging with real-time dashboards for
production and reliability KPIs, including Avg Ton/Hour.
• AI & predictive maintenance: introduced thermal imaging and structured visual inspection programs;
currently developing an AI-powered predictive maintenance platform (PyTorch, YOLO, OpenCV) for motor
anomaly detection and equipment health assessment.
• Reliability engineering: re-engineered the auto-bundling machine on the pipe mill line, improving reliability
35×; led the Cut-to-Length Modernization, redesigning the servo-controlled flying shear system with a
modern servo architecture while reusing existing hardware, avoiding major capital expenditure.
• Automation & safety: automated overhead crane control and protection systems, extending spare-part life
by up to 200% and improving safety.
• Training & culture: rolled out Precision Maintenance and TPM training programs, created a Do/Dont
manual for operators, and integrated production staff into preventive maintenance routines.
• Asset management: established critical spare identification, safety stock, and ABC inventory optimization,
reducing cost and downtime.
• Safety performance: maintained a zero-incident safety record across overhead crane operations (14
cranes) under electrical department oversight.
• Cost optimization: redesigned the VFD spare-parts strategy — standardizing on 1-2 higher-capacity,
reprogrammable drives to cover multiple machine variants instead of stocking a dedicated spare for each —
machine spare-parts cost from SAR 350, 000 to SAR 30, 000 (~91% reduction).
• Impact: delivered equipment life improvements of up to 600% and maintenance time reductions of up to
30% through lean maintenance and Kaizen initiatives.

• Led root cause analyses and resolved recurring electrical and mechanical failures.
• Troubleshot and programmed AC and Servo Drives; diagnosed and modified PLCs and HMIs to eliminate
equipment faults.
• Coordinated with electrical and mechanical teams to implement long-term fixes.
• Managed spare parts planning, sourcing replacements, and recommending alternatives.
• Maintained historical maintenance records and issued incident and resolution reports.

• Programmed and configured variable frequency drives, performed diagnostics, and designed control
systems.
• Provided post-sale technical support and customer engagement on performance issues.
• Delivered technical training seminars and presentations to clients and industrial stakeholders.
• Performed field visits for hands-on troubleshooting across industrial applications.