Maintenance Planning Engineer
Maaden Phosphate Company
Total years of experience :10 years, 0 Months
• Planning, monitoring, and controlling progress according to the defined measurement criteria and work breakdown structure.
• Performing various SAP transactions to perform regular planner duty that includes, but is not limited to, opening/initiating internal orders, notifications, maintenance work-orders, planning the activities with required resources, ordering the materials, and track all maintenance activities within respective area
• Plan for equipment isolation and safety precautions and estimate job step craft man-hour requirements.
• Prepare weekly and daily schedules by reviewing backlog and coordinating work requirements to comply with operation rankings
• Ensure availability of all resources required are met and available, prior to scheduling work, and obtain approval of the schedule updates maintenance order status & follow up until completion of orders.
• Monitor the progress of the maintenance daily and give feedback to maintenance supervisor and supporting the execution team.
• Ensure the history is updated and technically completed on all works orders prior to closing them.
• Ensure onsite availability of all materials, manpower and service requirements.
• Process the return of all support equipment and machines (i.e., crane, forklift, air compressor, flood glitch, etc.)
• Daily contact/coordination with concerned parties that includes Operations Foremen, Maintenance Supervisors, and personnel to clarify work scopes on Maintenance Work Orders, required resources, status update, and the path forward.
• Prepare detailed job step plans in proper execution sequence, with details of craft man-hour and crew size requirements for each step
• Turnaround budget preparation, cost optimization and cost controlling through all the phases of turnaround management cycle.
• Kick-off meeting with OEM/Vendor and execution contractor.
• Planning and preparing the job package of static and rotary equipment based on equipment history, site visit, referring GA drawing and isometric and using Navisworks 3D module.
• Considering information for job pack preparation of equipment like job method statement, material identification as per job scope, resource, drawings, isometrics, and procedures, lifting plans, blind list, execution checklist and EHS requirement.
• Conducting site visit with maintenance, operation, and inspection to evaluate the scope of work and resource requirement.
• Preparation of job method statement for Shutdown and Pre-Shutdown Activity.
• Coordinate with scheduler to prepare the schedule as per JMS in primavera P6 and integrate with master schedule to identify the critical path.
• Initiation and expediting the spare procurement process in the close coordination with material and inventory department to ensure the delivery of time.
• Preparing the material catalogue detail for cataloguing in Oracle.
• Material technical evaluation based on received quotation from vendor.
• Working on Oracle like Material Management, PR of Material, Material Tracking (Long lead item), Checking of BOM, spare availability, compliance, and repair WO.
• Knowledge/Proficiency in MS Excel, MS Access etc., is highly desirable
• Worked as a Turnaround Planning Engineer in Reliance (SEZ/DTA-Plant).
• Co-ordinate with plant, Preparation of Shutdown and Pre-Shutdown Schedule.
• Follow Stage gate procedure for Shutdown/Turnaround related planning.
• Making Shutdown Plan/schedule as per Job list and adding resources in primavera p6.
• Preparing/Making Job pack, job scope & tracking sheet.
• Develop detailed job plans that include the following steps, durations, material, and equipment needs and cost estimates: Resource requirements, Safety Plans, Efficient job tasking to guide field crews, Repair procedures, associated drawings and specifications, sequence of scheduling, Material & equipment needs, Gantt chart for complete job, Total hours & Cost estimate.
• Communicate daily with execution supervision during various phases of the turnaround to understand effectiveness of plan.
• Working on primavera and Microsoft Project for Scheduling/Monitoring.
• Monitor M&I Job for making daily progress report and Daily Analysis for Delay and Gain, Making Daily Progress and Cumulative Progress Report.
• Working on SAP RP2 & P10 (PM & MM) like Material Management, Functional location creation, Assets BOM creation, Tag creation, PR of Material, Closing Inspection list and Permit system, Material Tracking (Long lead item).
• Attended Reliance Safety Management Training courses (OMS, PTW, Work at height, Line break, confined space, Environmental Safety).
• Work closely with the Reliability Engineer to develop and communicate relevant KPI's for the maintenance team e.g., PPM Compliance %, Overdue PM's, Schedule Adherence, MTBF, % PdM Executed.
• Plan, estimate, and coordinate all aspects of maintenance and project activities associated with the Maintenance Shutdowns.
• Maintain LFI report during shutdown & tracking of recommendations of Inspection.
• Leadership, communication, decision making and problem-solving skills with a proven track record for effectively collaborating and working well within a team.
• Supervising repairing of rotating equipment, Centrifugal Pumps and compressors, Twin Lobe Blowers, Submersible Pump, and different types of Positive displacement reciprocating and gear pumps.
• Skilled at handling multiple tasks & projects in challenging environments with excellent relationship management skills & the ability to relate to people at any level of business & management.
• Maintaining spare parts inventory.
• Material purchase requisition, Material & Resource management as per plant and projects.
• Maintain LFI report during shutdown & tracking of recommendations of Inspection.
• Breakdown analysis, why why analysis.
• Inspection of new equipment’s as per requires designs.
• Preventive Maintenance Reports & Monthly reports generation.
• Rotary and stationary equipment history reports and analysis.
• Documentation in SAP system.
• Training need identification of department employees, training scheduling, and evaluation and maintains records.
• Giving instructions for usage of safety equipments during doing the jobs to prevent accidents.
• Job safety analysis and risk assessment during maintenance activities.
• Preparing Job RA, TBRA, HITRA, and implementation accordingly.
• Process Safety Management audits, and OMS implementation in plant.