Maintenance Director
El Masrya Concord for Contracting and Modern Industries
Total des années d'expérience :16 years, 0 Mois
Installing of new production and utility machinery.
Manage project team during project execution.
Report and escalate to top management as needed.
Prepare the PM plan, CIL plan, Maintenance budget and outline needed resources.
Prepare documentation for ISO 9001 certificate.
Planning and installing of new machinery, Ovens, Packaging machines and conveyors.
Arranged the required equipment, electrical and mechanical parts.
Define project scope, schedule and cost.
Monitor and report on project progress.
Manage project team during the execution of the project.
Coordinate internal resources and third parties/vendors for the flawless execution of projects.
Prepare the projects plan, budget and outline needed resources.
Prepare the PM plan, Maintenance budget and outline needed resources.
Using financial analysis to make sure all maintenance tasks are completed within budget.
Ensure that all maintenance tasks are delivered on-time.
Measure & evaluate maintenance department performance using appropriate systems, tools and techniques.
Report and escalate to top management as needed.
Establish and maintain relationships with third parties/vendors.
Create and maintain comprehensive maintenance & project documentation.
Create the monthly cash flow report.
Analyze technical data, design, specefications, supplier facilities and availability of the required parts and equipments
Prepare PR & GRN on SAP for all the required parts & equipments for the Engineering departments
Complete the PR & PO attachements, comparison sheet and material files for review from Procurement unit head.
Coordinate with finance for payment request for the suppliers & contractors.
Negotiate with Local/External suppliers on lead time, cost and quality.
Preparing and Applying the Continuous Improvement Plan to improve machine availability & production cycle time.
Prepare the projects plan, budget and outline needed resources.
Define project scope, schedule and cost.
Monitor and report on project progress.
Using financial analysis to make sure projects are completed within scope & budget.
Manage project team during the execution of the project.
Monitor and report on project progress.
Coordinate internal resources and third parties/vendors for the flawless execution of projects.
Measure & evaluate project performance using appropriate systems, tools and techniques.
Prepare the PM plan, Maintenance budget and outline needed resources.
Using financial analysis to make sure all maintenance tasks are completed within budget.
Ensure that all maintenance tasks are delivered on-time.
Measure & evaluate maintenance department performance using appropriate systems, tools and techniques.
Report and escalate to top management as needed.
Establish and maintain relationships with third parties/vendors.
Create and maintain comprehensive maintenance & project documentation.
Create the monthly cash flow report.
Analyze technical data, design, specifications, supplier facilities and availability of the required parts and equipment.
Prepare PR & GRN on SAP for all the required parts & equipment for the Engineering departments.
Complete the PR & PO attachments, comparison sheet and material files for review from Procurement unit head.
Coordinate with finance for payment request for the suppliers & contractors.
Negotiate with Local/External suppliers on lead time, cost and quality.
Preparing and Applying the Continuous Improvement Plan to improve machine availability & production cycle time.
Define project scope, schedule and cost.
Monitor and report on project progress.
Using financial analysis to make sure projects are completed within scope & budget.
Manage project team during the execution of the project.
Monitor and report on project progress.
Coordinate internal resources and third parties/vendors for the flawless execution of projects.
Measure & evaluate project performance using appropriate systems, tools and techniques.
Prepare the projects plan, budget and outline needed resources.
1- Sets, schedules and manages the plant preventive maintenance (PM) to guarantee the efficiency
of Conveyors, Atlas Copco Air Compressor, Boilers, Overhead Conveyors, Air & Water
Chillers, Generators (Byrne, Cummins and Caterpillar), Packaging Machines (Bosch
Tevopharm, Cavanna & Ulma) and truck weighing bridge.
2- Sets the annual maintenance budget in corporation with Maintenance GM, and manages
expenditures to ensure its commitment to the approved budget.
3- Machine ranking study to set the PM plan according to the criticality of the machine.
4- Analysis of machine breakdown time (MTTR, MTBF).
5- Apply new systems to reduce breakdown and increase product quality (QFD - CIL -
Visual Control).
6- Monitors the use and inventories of spare parts, maintenance supplies and approves ordering
when necessary.
7- Monthly technical audit for the machines & equipment.
8- Monitors the repairing of emergency breakdowns, the operation of plant equipment and systems
constantly, to minimize unplanned downtime.
9- Follow up on implementation of Maintenance Procedures to achieve the department targeted
KPI’s.
10-Works on the needed improvements to increase the productivity.
11-Coordinate activities with all other departments (Quality, Production, Warehouses & Stores).
12- Planning for the volume and specifications of the required mechanical, electrical, fabrication
and HVAC spare parts to reduce the machines downtime, besides the Inventory of spare parts.
13-Coordinate activities with maintenance subcontractors.
14-Making external maintenance contracts (AMC) for some equipment in addition to supervising
their enforcement such as HVAC, Boiler chemical water treatment, Truck Weigh bridge
calibration, Generators.
15- Assist and advise in the planning and installation of new machinery and process equipment, and
assist outside contractors in the execution of new projects.
16- Prepare maintenance weekly reports (Expenses, PM execution, Critical Breakdown and PR
created)
17-Identify the requirements and materials required for the maintenance department and its request
from the Procurement Department through SAP by creating PR & GRN.
18-Create Physical Inventory Stock & update stock consumption on SAP.
19- Facilitate the implementation of GMP & the alignment with the food safety System (HACCP).
20- Directs, maintains, and enforces the safety program for the maintenance department; reviews
safety records to uphold standards of maximum safety for all maintenance personnel.
21-Ensures that maintenance personnel are adequately trained, equipped, and motivated so that the
maintenance programs can be accomplished in a safe, timely, and cost-effective manner.
22-Evaluating of workers through annual reports by coordination with the Human Resources
Department.
Electrical data collection (Line, Machine, Type, Model and Quantity) for (Sensors, Touch screen, Inverters and PLC).
Design Layout & Code System for (Sensors, Touch screen, VFD’s, Control panels and PLC).
Machine ranking study to set the PM plan according to the criticality of the machine.
Programming Induction and Servo motors Variable Speed Control (Vacon, ABB, Yaskawa, Danfuss, SEW and Omron).
Calibrate the Temperature controller (Omron, Honeywell and IR sensor) for Ovens (Electric & Gas), Tempering Machines and Packaging Machines.
Metal Detector Loma calibration for all production lines (Biscuit, Chocolates, Wafer & Cake).
Automation troubleshooting for; Touch Screen (Upload and Download) Parameter, Servo & Induction motor drives (Vacon, ABB, Yaskawa, Danfuss, SEW and Omron), PLC (Mitsubishi, Siemens).
Applying the PM plan (Supervision and Hand works) for W+D line, Buhler Mass Line, Wafer Line (HAAS & Hebenstreit), Laser Cake Lines (Cup & Layers), HAAS Rulokat Line, Packaging Machines (Sapal, Bosch, Tevopharm, Eurosicma, Cavanna), Biscuit Line (Imaforni, Laser & Eskort).
Increase the safety in machines to protect operator from accident by adding safety switches for (Packaging machines, Chocolate tanks and Dough mixers)
Design OPL's (One Point Lesson) and KAIZEN.
KPI's study (MTTR and MTBF).
Apply new systems to reduce the scrap, increase quality & productivity (QFD - CIL & Visual Control) Engineering Analysis (Fish Bone - Pareto and Why-Why) to reduce breakdown time.
Inverters speed synchronization for the production lines conveyors and machines to reduce the change over time.
Load cell calibration for mixers & silos.
Electrical power distribution & control panel design and commissioning for new lines.
Install and commissioning for the new production lines, utilities and machines.
All production lines & machines troubleshooting (Conveyors, Mixers, Ovens and Packaging machines). Directed & instructed Maintenance team and monitored expenses with optimum utilization of resources; ensured zero accidents with zero loss to man, plant & machinery.
Planning and Supervision of Preventive Maintenance plan.
Training the technicians on applying the Preventive Maintenance plan and new systems (TPM, 6’S and KAIZEN).
Applying the TPM (Total Productive Maintenance) in the new Fully Automatic Washing Machine factory.
Install and commissioning the new Fully Automatic Washing Machine factory (Elevators, Presses and Production Line).
Design the Automatic control panel for the (Production Line conveyors, Presses and Hydraulic elevator).
Design Spare Parts Stock control & Code system. KPI"s study (MTTR - MTBF - OEE - Skill Matrix). Preparing and Applying the Continuous Improvement Plan.
PLC program troubleshooting & modification for all machines and Presses.
Production process & machine cycle time improvements. Engineering Analysis (CE Matrix - Fish Bone - Pareto - Machine capability - Process capability - why why).
1- Converted all the machines electrical circuit from classic control to micro-controller to be fully
automatic machines.
2- Modify the machines electrical control circuit using inverters for speed control.
1. Home Automation using Atmel89c and Visual Basic. 2. Design of ElKurimat Thermal Power Station using Matlab.
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