Maintenance Engineer
National Oilwell Varco
Total years of experience :20 years, 8 Months
• Lead the Breakdown Maintenance Team in repairing and troubleshooting different types of machines.
• Take charge in repairing CNC and PLC controlled machines from different machine tool builders like;
o Dorries Scharman, Alpha 1000 & DBF630 - Horizontal Milling with Siemens Control.
o Mazak, Integrex, Variaxis and QTN & H500 Series machines - Mazatrol T&M32, Mazatrol 640 Fusion and Matrix.
o Mori Seiki Lathe and Vertical Milling machine with Fanuc Control.
o Monarch Vertical milling machine with Fanuc control
o Doosan Horizontal milling and Lathe machine with Fanuc 31i.
o Toyoda Horizontal Milling machine with Fanuc 31i
o Kitamura Horizontal Milling machine with Fanuc 16i.
o Emag Lathe/Grinding machine with Siemens Control
o Trevisan Horizontal Milling with Facing Head - Fanuc 31i control
o Bryant Grinding Machine,
o Clayton Steam Generator with Allen Bradley PLC
o Studder Grinding Machine with Fanuc 16i
• Generate and close work orders in the event of machine breakdown and recovery.
• Check CNC machine accuracy using Renishaw QC20 Ballbar and generate report based on recorded data.
• Perform mechanical troubleshooting like;
o Linear guide and bearing replacement
o Ballscrew replacement
o Turret/tailstock/headstock/ATC alignment.
• Supervise the overall flow of maintenance department.
• Perform inspection, installation, levelling and alignment of all new CNC machines, Water Jet Cutting Machines, Schenck Balancing Machines, Polysoude Automatic Orbital Welding Machines, Ventil Valves Testing Machines.
• Plan, organise and implement a planned preventative maintenance programme for all plant and machinery and perform unscheduled equipment maintenance breakdown as and when required.
• Troubleshoot, maintain, repair or replace pneumatic, hydraulic, electrical and mechanical components and CNC control boards and PLC Systems and conduct testing with machine like:
I. Cei waterjet cutting machine with JetEdge Ultra High Pressure Pump.
II. You Ji Vertical Turning Lathes with Fanuc CNC Control.
III. Dugard Slant Bed and flatbed CNC Turning Lathes with Fanuc Control.
IV. Cosen PLC Controlled Band Saw cutting machine.
V. Atlas Copco GA90VSD Air Compressor with Siemens frequency inverter.
VI. Stingray Parts Washer Machine.
VII. Schenck Balancing Machine.
VIII. TOS Horizontal Boring Machine with iTNC530Heidenhain Control
IX. PraxAir High Velocity Oxygen Fuel and Arc Spray.
X. ABB Robot used in High Velocity Oxygen Fuel and Arc Spray Coating.
XI. Vacuum Pressure Impregnation with Siemens Step 7 PLC.
XII. Curing Oven with Siemens Step 7 PLC.
XIII. TOS Varnsdorf Horizontal Boring machine with Heidenhain iTNC530i control
• Ensure that all work activities are carried out in an efficient, professional and tidy manner and provide regular progress updates and report any new findings or issues.
• Coordinate the supply and flow of all consumables, materials, replacement parts and components and accurately record repairs, time, parts and materials.
• Manage workloads and prioritise resources to ensure that all work is completed on time and ensure that a high standard of personnel / workshop / equipment / machines and tooling cleanliness is maintained.
• Perform troubleshooting and repair in all CNC machines like You Ji Vertical turning lathes with Fanuc controls and TOS Varnsdorf Horizontal Boring machine with Heidenhain iTNC530i control.
• Perform troubleshooting in the event of machine breakdown with machines like the EWM Hightech Welding machine, Fronius Orbital Automatic Welding machine, You Ji Vertical turning lathes, TOS Varnsdorf Horizontal Boring machine and the DEUMA Pipe Transport System controlled by Siemens S7 PLC.
• Made a PLC program for the S7-300 CPU PLC for the DEUMA Pipe Transport Conveyor System.
• Commissioning of the Pipe transport system. Implementation of the PLC program and testing.
• Perform alignment for the conveyor system for the pipe transport system.
• Configure the Sew Eurodrive Frequency Converters for different applications on the pipe transport system.
• Perform installation, servicing and commissioning of different CNC machines from different Machine Tool Builder like;
o Yamazaki Mazak CNC Machines (Variaxis, Quickturn Nexus and Milling)
o Cincinnati Milacron Machines
o Doosan Machines (Vertical and Horizontal Lathes, Milling and Boring machines
o Hartford Dual Colum Horizontal Milling Machines
o Giddings and Lewis with Allen Bradley Controls
• Perform Machine troubleshooting in the event of machine breakdown by using the diagnostic function of the CNC machine like tracing the Ladder Diagram, checking I/O status of all signals, PMC diagnostic for Fanuc
• Performs parts replacement of the CNC machines like Ballscrew for different axis of the machine, servo and spindle amplifier as well as the servo motors, NC unit replacement, I/O module, Memory module, Position Coders and Absolute Encoders, Bearing for the different axis and Headstock, spindle carthdrige.
• Perform machine accuracy check, leveling, after every installation and test every machine functions.
• Perform SRAM Back-up, and back-up CNC and PMC Parameters after every installation.
• Perform preventive maintenance and machine calibration to utilize and ensure machine accuracy and efficiency.
• Perform installation and interfacing for the Renishaw Probing System, Bar Feeder interfacing with CNC Lathe Machine.
• Perform machine parameters restoration in the event that the Main Board and Memory Board were replaced.
• Perform machine alignment (e.g. Turret, Different Axis, Automatic Tool Changer (ATC), Automatic Pallet Changer (APC), Rotary Table, Spindle Orientation and Headstock alignment).
• Travel all over the Middle East to handle costumer needs and after sales service in terms machine breakdown, machine consultation
• Assist the German Service Engineer during the installation of additional line (Spun Bond Melt Blown Melt Blown Spun Bond).
• Assist in commissioning the |Edelmann Winder/rewinder machine.
• Responsible in maintaining the good quality of the rewind non-woven fabric.
• Calibrate the Load Cell of the rollers to conform the standard.
• Perform preventive maintenance in the Chillers.
• Replace Damage Frequency drives.
• Perform preventive maintainance in the Reifenhauser Non-woven machines, Edellman Winder/Rewinder.
• Set-up newly arrive CNC machines like Mori Seiki Machines, Citizen Cincom, Brother Machines, Takahashi Machines, Kitamura Machines, Tsugami Machines and Toshiba Die Casting Machines and Ikura Seiki Barfeeders.
• Responsible in maintaining the working Condition of all Computer Numerical Control Machines (CNC Machines), Die Casting Machines, Compressors, and Standby Generators by implementing and performing Preventive Maintenance.
• Responsible in the Installation and Configuration of New Variable Frequency Drives (Inverters), and backed-up the Parameters in all CNC Machines.
• Responsible in replacing Damaged High Power Transistor modules (IGBT), Linear Scale (Heidenhain) Position Coder, Absolute Encoder and Incremental Encoders..
• Repair and troubleshoot Die Casting machines(Toshiba) with PLC controller (Toshiba) as well as the Melting/Holding Furnace (Daiki)
• Repair and troubleshoot all types of CNC machines (Vertical, horizontal milling center and high precision lathe.
• Repair damage Power supply, Stepper motor controller and servo motor amplifier.
• Troubleshoot Programmable Logic Controller, (Mitsubishi and Toshiba).
• Perform Preventive and Corrective Maintenance of all Screw and Piston Type Compressors(Kobelco, Atlas Copco, Hitachi)
• Maintain the good working condition of Pneumatic and hydraulic elements and compressors.
1. Studied Industrial Motor Control 2. Studied Electrical Circuits 3. Do 3-phase motor and transformer rewinding 4. Do Transformer banking 5. Studied PLC programming.