عمر سامي

▪ Manage the maintenance and the general store activities for Mattex Group in Jeddah, which consists of 2 Companies, 4 purchase offices and 6 factories distributed over 3 locations in industrial city phase 5, managing a total of 64 maintenance headcount.
▪ Controlling the ordering process through sifting of similar items with different codes, assigning new Maximum ordering quantity and finding local alternatives. This resulted in a reduction of 5% of the store ageing inventory although the purchase orders amount increased.
▪ Utilizing the company tools (ERP system and Power BI) to capture the downtime percentage and the performing the needed Breakdown analysis.
▪ Reduction of the downtime initiated because of the Utilities by 5%.
▪ Implementing the Existing PM program achieving schedule compliance of 80%.
▪ Implementing the Sub Cost center module in order to assign the issuance order to the specific machine, which helps in determining the most consuming assets.
▪ Introducing the Maintenance Module to be incorporated with the ERP system so that the Work order process is digitized to produce more accurate results
▪ Enhancing the capabilities of the Maintenance Personnel through Trainings on bearings, lubrication, breakdown analysis and dealing with the ERP system to find the spare parts.
▪ Member of the Technical and project management department responsible for the selection of the new machinery.

Responsible for the maintenance activities of the Open End Spinning, Fleecing and Beaming Sections as well as the transport workshop.
▪ Creating PM Programs for the newly joined sections such as the Open End spinning and Fleecing.
▪ Creating Min-Max stock program for the different facility sections.
▪ Responsible for Providing technical assistance to other maintenance department teams as a technical support engineer in matters such as spare parts selection, utility monitoring and electrical troubleshooting.
▪ Implementing the created PM programs upon which the evaluation of the technicians will be based upon as per higher management directives.
▪ Introducing Maintenance KPIs such as Number of work orders created from PM program compared to Number of Work orders.
▪ Selecting the locations and executing the location drawings for the new purchased machine such as cloth inspection table, adding another creel to beaming machine head and replacing the winder of the fleecing line.

• Monitoring the Schedule compliance percentage and improving the planning and scheduling to increase wrench time of technicians.
• Preparing the necessary scheduling and planning for the yearly turnarounds (Shutdowns).
• Improving the preventive maintenance plan to include basic predictive maintenance techniques based on visual inspection and monitoring the process parameters.
• Creating work orders based on the Preventive and predictive maintenance plans and giving the adequate priority and time to execute those tasks.
• Creating a comprehensive list of all materials in the MRO store. All spare parts for different facilities were concentrated in a central hub. Continuous ABC analysis is performed to identify the vital few components. This led to substantial reduction in M&R cost.
• Creating Cost reduction programs related to utilities which achieved a reduction in the power consumption of air compressors by 5%.
• Calculating overhead costs with finance department to determine opportunities of cost reduction.
• Managing by leading KPIs such as MTTR and Schedule compliance.
• Managing by Lagging KPIs such as MTBF and Maintenance Department cost percentages.
• Using M&R analysis tools to help identify problems and solutions such as Ishikawa analysis, 5 whys and root cause analysis.
• Leading Projects such as the Transfer of Nadiya Dates Facility operations from Dubai to Jeddah. (Chopped,
paste, Stuffed and chocolate coated).
• Leading Projects such as Transfer Tin buckets manufacturing section to a new location. (Total of 22 Machines).

Job Responsibilities:
• Team leader to a group of engineers whose mission is to search for the areas of improvement of the production process.
• Recreating the preventive maintenance plan taking into account reliability concepts to achieve the minimum down time (Planned and unplanned) with the least resources.
• Creating plans for some autonomous tasks to be performed by the production operators to maintain the cleanliness, reliability of specific machinery.
• Creating Channels with various machine suppliers to seek assist and repair/modify machineries.
• Studying the newly joined factories demands in terms of utilities and submit the studies to ensure the continuation of the production process without interruption due to utilities.

Achievements
• Executing the plans for the installation of 1500 KVA transformer instead of 500 KVA as well as upgrading the main electric panel boards to support the new KVA rating of the transformer.
• Creating the plan and follow up installation of more than 30 steam traps in NCTF to overcome back pressure in steam condensate line.
• Overhauling of 12 TPH light oil (Diesel) boiler with troubleshooting and solving of loss of flame problem.
• Creating the P&I drawings for the installation of Alfa-Laval cooling system to decrease the product temperature from 120 C to 50 C.
• Installing Sesame flow weighing scale from Akyurek Turkey to calculate the amount of waste in the Sesame line.
• Preparing the utilities studies related to electric demand and chilled water demands of Cortina factory. As a result, a 200 TN chiller was purchased to be used as standby.
• Executing the plans of installing 1500 KVA transformer instead of 500 KVA to meet the expansion plan as well as replacing the associated main electric panel to meet the new Current ratings for the Tema Plant.
• Inaugurating and installing the machinery for Nadiya Dates factory which included Fumigation, washing, grading and vacuum sealing machines.

Job Responsibilities:
• Supervision daily operation tasks and assigning tasks to maintenance personnel on a daily schedule basis.
• Preparation of the Daily, Weekly and monthly reports to all the works performed by the maintenance department.
• Works as reliability Engineer to decide on best practices to preserve machinery in terms of selecting spare parts resources and modifying the production process to yield better and cost saving performance.
• Submitting the yearly Spare parts expenditure Budget.
• Co-ordinates with the Project development department to erect the various factory project such as renovation of the stores, building new quality labs and logistics building, removal of equipment on older platforms ad reinstalling them after erecting new platforms according to industrial city standards.

Achievements
• Project manager for erecting 6.3 TPH boiler manufactured by Forbes Marshal, India together with Condensate pumps and temperature control valves. This has a great impact in reducing the expenditures over water and diesel used by selecting the adequate boiler according the production needs instead of over specified old system. (September 2016)
• Planning and supervision the execution of Modern Steam condensate return system which led to a reduction in the water consumption by 20% and diesel consumption by 15%. (September-November 2016)
• Project manager for the erection of 120 TR chiller unit (Carrier) including the designing of the chilled water piping and selecting the supply and circulating pumps. (January 2016)
• Preparing electric study upon which a new 500 KVA transformed was purchased so that to increase the power supplies to meet the future production requirements.

Job Responsibilities:
• Installation and commissioning of production lines control systems, Level sensors, load cells and temperature controllers.
• Issuing Purchase request for daily materials
• Creating and updating the list of machines.
• Creation of the Preventive maintenance plan and the maintenance checklist, from the scratch, for all the machinery.
• Create the Lockout/Tagout Procedures to help eliminate the job injuries and near accident events.
• Team leader to a group of mechanical and electrical technician responsible for installing various machines such as sesame peelers and sesame cleaning machine.
Achievements
• Team leader responsible for the relocation of 65% of the overall machinery of the factory including the electric, steam, Pneumatic, Chilled water and raw materials connections for the purpose of installing epoxy layer to the factory floor.