Equipment Improvement
Matrix Solutions
Total years of experience :21 years, 7 Months
Planning, designing, and prepare contents of maintenance training programs, consultancy for manufacturing effectiveness.
Product owner, of special software for time effectiveness in factories, that leads to tremendous impact on Cost reduction and ROCE rising.
Consultancy and support for various manufacturing firms like food, beverages, sweets, paper, packing, fabrics, … etc. that includes:
o helping factory management in monitoring, control, and development of operational departments, using effective data gathering to be useful information with simple visualization.
o Improve decision making in planning and measuring stages, leads to accurate decision with measurable return on investment for each decision taken.
o Ability to find out current point solution, next period framework, and sustainable long plan for targets.
o For now, I’m a maintenance and reliability consultant for many manufacturing firms, specially steel structure factories.
Recruited by VP of 1 billion SAR working capital, in 7 factories group, leading 31 employee in maintenance departments across factories, to coordinate maintenance workers efforts to make sure employer's property like Machines, Equipment and Buildings are kept up.
Develop maintenance schedules and enforce them among maintenance staff, synchronized with responding to corrective maintenance required.
Contact and schedule subcontractors, repairmen and extra help as needed.
Perform administrative tasks as required, with tasks delegation to qualify lower teams' members and increase their expertise with KPI for each task.
TPM, Total Productive Maintenance preparation and implementation.
OEE Overall Equipment Effectiveness implementation and development to insure and measure equipment’s effective utilization.
Managed factories resources, progress, completion timeframes, and budget while exceeding key operational performance targets, with results that include:
Rebar factory
Gain 10% Reducing in time loss.
Gain 18% Decreasing in extra operation cost within 6 months.
Gain 12% Increasing machines availability from 58% to 70%, within 6 months.
Gain 25% Increasing in productivity of rebar factory from 4000 tons to 5000 tons per month.
Gain 12% Extra net profit/month added with 288 thousand SAR / month.
Gain 15% Increase in KPI for maintenance Deps. in both Rebar and C&B factories.
Cut & Bend factory
13% Reducing in time loss.
30% Reducing in breakdown time from 780 Hrs. to 545 Hrs. /month for 18 productive machines.
20% saving time in setup and adjustment with average 8 min instead of 10 min/product change.
28% Decreasing in extra operation cost within 8 months.
33% Increasing in productivity of C&B factory from 2500 tons to 3325 tons per month.
110% extra net profit/month added with 280 thousands SAR/month.
Workflow designer, and system required specification author of Maintenance module, and Production control module for integrated ERP Software. Workflow designer, and system required specification author of Maintenance module, and Production control module for integrated ERP Software.
Skills: Process Flow Charts · CMMS · Production Planning · Reducing Operating Costs · Lean Manufacturing
Monitors operation of plant equipment and systems effectiveness with measuring and control to notice and exploiting available opportunities, avoiding possible threats.
Prepares reports, analyzes data, and makes recommendations for improving plant operations and solving maintenance-related problems.
Initiates and carries out projects that improve efficiency and/or reduce operating costs.
Tracks, analyzes and improves key maintenance parameters such as asset utilization, maintenance cost, PM compliance, schedule compliance, Overall Equipment Effectiveness (OEE), etc.
Maintains safety, health, and environmental policies and procedures.
Ensures city, county, state, and federal regulations relating to the maintenance department are met at all times.
Directs, maintains, and enforces the safety program for the maintenance department; reviews safety records to uphold standards of maximum safety for all maintenance technicians, and production labors.
Participate in objective setting, plan development and KPI review of plant performance.
Initiates, implements, and manages the plant maintenance program based on best practices in the steel industry, with an emphasis on planning/scheduling and preventive/predictive maintenance.
Monitors the use and inventories of spare parts, maintenance supplies, and equipment with auto re-order upon minimum and maximum stock prepared previously.
All above well managed tasks lead to many amazing results includes:
40% reduction in maintenance target from 5% to 3% of total working hours.
7% turnover in maintenance team for 6 years with 2 Technicians out of 28.
96% average availability for all machines.
Zero accidents in 6 years of responsibility.
96% average KPI for maintenance team.
81% OEE for plant equipment and systems.
22% reduction in Spare parts inventories cost from 3.5 million to 2.73 million/year.
5% reduction in operation cost, leads to 12% increment in net profit.
• Installation, calibration and maintenance for Boilers equipment transferred from IBSF.
• Directing, monitoring and coordinating, sectional processes, evaluations and plans, to guarantee standard running conditions and optimum process productivity in accordance with daily / monthly schedules
• All electrical, mechanical, hydraulic and pneumatic maintenance for shaping, milling, horizontal laths, vertical laths, rolling, welding (MMA-MIG-TIG-SAW), flame cutting, plasma cutting, over head crane, press brakes, shears, tube bending, beveling, resizing, swage, panel welding, laser cutting, CNC cutting, Robot welding, Orbital welding, punches, pumps and cars' workshop.
• Preparing monthly reports on maintenance budgets and recurring costs. Executing internal audits to monitor levels of operational readiness procedures.
• Enforcing operation procedures as per ISO 9001: 2000 standards, auditing usage of spare parts, accordingly placing orders to ensure minimal turnaround time for critical repair work.
• Designing section budgets, and effecting cost cutting measures to maintain adherence to the same. Evaluating supplier bids, identifying suppliers for optimal cost effectiveness
• Conducting weekly and monthly preventive maintenance checks on automated heavy duty equipments and machines, to prevent unscheduled stoppages across all departments and locations.
• Identifying vendors, floating tenders, evaluating the same, leading and finalizing contractual details. Liaising with them and ensuring adherence to all deliverables
• Management for documentation system to improve my company in ISO 9001- 14001 for more development and progress gained.
• Enforcing obedience to safety regulations, reviewing safety manuals. Conducting monthly safety audits. Ensuring operational readiness of all safety and emergency equipment in the company
• Primarily responsible for electrical maintenance of all machines including shaping, milling, horizontal laths, vertical laths, rolling, welding (MMA-MIG-TIG-SAW), flame cutting, plasma cutting, over head crane, press brakes, shears, tube bending, beveling, resizing, swage and panel welding.
• Management for documentation system to improve my company in ISO 9001- 14001 for more development and progress gained.
• Disassemble for all equipments successfully to the new company location with highest speed and accuracy.
Work in many fields in power electric dep. My responsibility was as follow:
- Design and repairing for control panels
- Design and repairing for power distribution panels
- Design and repairing for automation systems.
- CNC M/C's maintenance and repairing.
- Deal with PLC systems hardware & software.
- Electronic boards repairing.
- Welding M/C's maintenance and repairing.
- Air condition's maintenance (supervisor).
• Electrical power distribution from medium voltage substation to low voltage substations panels.
• Motor rewinding workshop supervision.
• Electrical equipments repair supervision.
• Power factor correction for the main power networks.
• Assistant for electronic cards work shop supervisor.