Qa/Qc Engineer
Borouge - Abu Dhabi Polymers Company
مجموع سنوات الخبرة :16 years, 8 أشهر
- Ensuring prime polymer quality for immediate packaging and shipping of product.
- Custodianship of online FTIR detector from OCS for LDPE and XLPE additive and density measurement.
- Custodianship of online and offline film tape extrusion machines for gel and contamination analysis from OCS.
- Generation of monthly SPC (statistical process control) reports to ensure healthy instrument operation and accurate on-spec results.
- Generation of bi-annual product review reports by collecting and summarizing lab analysis results from online and offline equipment.
- Providing support in analysis of samples for timely delivery of results to operations side of the plant.
- Leading the team of day-staff technicians to maintain continuous operation of LDPE/XLPE analysis instruments, and providing necessary support to shift technicians and plant operations teams.
- Classification of manufactured product based on quality test results, and communicating the relevant information to upper channels.
- Providing timely and concise instructions during for shift personnel during plant startup regarding product testing, and promptly addressing any arising concerns.
- Mentoring, training and supervising young Emirati trainees to fulfill their development programs, and newly assigned roles.
- Successfully completed the project for in-house development of a one component polyurethane waterproof coating with a 25% profit margin versus local competitors.
- Developed a new range of water-based cold bitumen damp-proof coating aimed at the retail market, with focus on emulsion storage stability.
- Successfully lead the technical side in the rollout of a new product for soil stabilization and dust proofing.
- Carried out the development project of the full range of acrylic, silicone and silicate based decorative plasters and architectural facade renders, and ensured the products met all acceptance criteria of ASTM and ETAG004 compliance standards.
- Provided technical support to all divisions of DCP International regarding acrylic and dispersion based adhesives, sealants, coatings, repair and waterproofing products.
- Participated in the design and enhancement of technical data sheets for new and existing products to gain a greater competitive edge in the market.
- Project leader for in-house development of the entire range of one component polyurethane based waterproof coatings and sealants.
- Lead the initiative for proper implementation of ASE thickeners in manufacturing, resulting in 10% cost saving in SBR latex based products with greater performance.
- Developed one component and two component cement-based waterproof coatings, and conducted all necessary tests for compliance with strict performance requirements.
-Direct experience in the manufacturing and testing of a wide array of personal health and care products, from a number of key clients including Johnson & Johnson and Procter & Gamble.
-Direct experience in the commercial qualification of new product formulations, starting from pilot test batches through to full-scale production.
-Direct experience in operating and maintaining FTIR, HPLC, GC, AA and MS instruments.
-Conducted all testing of raw materials, in-process batches and line samples in adherence to validated test methods according to approved customer specifications.
-Liaised with the customer in carrying out test method validation and transfer for new product tests.
-Conducted monthly SEE-audits in the lab as part of my duties as a member of the health and safety committee, and reported the results for discussion during committee meetings.
-Showed an exceptional capacity to prioritize work according to a 'first come first serve' basis, whilst accommodating 'hot-list' items and production line demands.
-Ensured that full product testing and release were done in an efficient and timely manner.
-Collaborated continuously with the compounding department to ensure that manufactured products meet customer specifications.
-Gave necessary chemical adjustments to in-process and finished batch samples.
-Performed material balance calculations based on the varying strength of received raw materials.
-Operated and controlled Agilent High Pressure Liquid Chromatography (HPLC) machines, Agilent Gas Chromatorgraphs (GC), Perkin-Elmer FTIR, and Agilent UV-Vis spectrophotometers, in addition to traditional wet chemistry experiments to carry out sample and raw material testing.
-Ensured that all instruments and machines were calibrated and maintained according to specified schedules and expiry dates.
-Maintained an official and detailed log of the data and results from all performed testing.
-Ensured the continuous and smooth operation of 3 independent juice filling lines.
-Addressed all arising issues swiftly and in a demonstrably efficient manner.
-Applied lean-manufacturing practices to improve efficiency and cut costs.
-Assumed responsibility for Kaizen activities and ongoing CI suggestions.
-Lead, trained and guided the production team towards achieving daily production targets.
-Hands-on troubleshooting and solving of technical problems whenever necessary.
-Prepared and implemented action plans, and distributed the workload effectively to maximize overall equipment efficiency of production machines.
-Examined the needs for training and provided on the job training to departmental personnel.
-Prepared management information reports to ensure progress in the department.
-Operated and controlled a novel pilot reactor setup for catalytic emissions abatement.
-Successfully completed two industrial contract projects, which lead to the renewal of major funding contributions for the lab.
-Developed, for the first time, a systematic method for the combined monitoring of temperature and concentration gradients within a monolithic catalyst, using IR Thermography and Mass spectrometry.
-Proved the effectiveness of my method in providing reliable measurements of the necessary kinetic data for computer models.
-Completed a four months contract project for analyzing the performance of two, Dodge Ram NOx Storage & Reduction (NSR), catalytic converters under variable compositions of reducing gases.
-Completed a three months contract project for comparing the efficiency of two different diesel oxidation catalysts (DOC), by mapping surface temperature profiles during hydrocabron oxidation.
-Designed an auxiliary reactor inlet port for continuous outlet gas sampling, and a high-temperature heat resistant fused silica capillary platform that is compatible with the auxiliary inlet port.
-Developed a protocol for running TPD and pulsed hydrogen-chemisorption catalyst characterization techniques for a state-of-the-art catalyst powder reactor.
-Maintained continuous operation and proper functioning of lab equipment by conducting regular daily and weekly checks.
Thesis titled: Spatially-Resolving Concentration and Temperature Gradients during the Oxidation of Propylene published in Applied Catalysis A: General, June 2009. Presenter at the 57th Canadian Society of Chemical Engineers Conference, Edmonton, Alberta, October 2007. Presenter at the 20th Canadian Symposium on Catalysis, Kingston, Ontario, July 2008.
Thesis titled: Spatially-Resolving Concentration and Temperature Gradients during the Oxidation of Propylene published in Applied Catalysis A: General, June 2009. Presenter at the 57th Canadian Society of Chemical Engineers Conference, Edmonton, Alberta, October 2007. Presenter at the 20th Canadian Symposium on Catalysis, Kingston, Ontario, July 2008.
Bachelor Degree Graduation Project: Team leader for the detailed design of a 4500 tonnes/day double contact 98% sulfuric acid production plant with special focus on the contact reactors. Distinguised Student Award Competition: Coded a comprehensive m-file MATLAB program for a new solubility model, and submitted the written program and its simulation results as a report to participate in the above-mentioned award.