Maintenance Manager
BP / Castrol
Total years of experience :15 years, 6 Months
Heading Maintenance, Project, Utilities & Technical procurement functions for world class, 60 KMT/annum, lubricant blending plant. ( Direct Reports / Team : 5 / 16)
Joined the project of construction of lube blending plant worth 50M$ during construction stage. Directly supervised 4 contractors, heading E & I function responsible for all MV, LV, low current, instrumentation, control & IT & S works. Also coordinated with utility provider (MARAFIQ) & municipal authority (RC) for energization of the system. Led Fire & Safety contractor along with consultants to ensure that all works are as per HCIS, NFPA & BP regulations & standards.
Responsible for liaising with filling & blending OEM’s, installation of equipment & support during testing & commissioning activities. Spearheaded handing over activities from project team & conducting safety/hazard/risk assessments for ensuring safe & timely testing & commissioning.
Responsible for hiring & mentoring of plant team, establishing KPI’s & conducting performance related audits.
Accountable for ensuring maintenance regimes are developed and implemented before plant start-up & in-line with ISO-9001, 14001 & OHSAS 18001 guidelines along with BP standards.
Implemented risk based maintenance approach defining preventative + predictive maintenance & establishing maintenance contracts, spares inventory and ensuring optimal utilization of budget and guaranteeing highest level of service.
Participated in sustainability initiatives and head of plant CI committee. Key Member of ERP and CMC.
Accountable for adherence to maintenance & CAPEX (1M$) execution within budget and schedule.
Led NPR (non-product related) purchase with value up-to 3M, strong understanding of financial policies.
Liaison with BP, regulatory authorities, OEM’s, service providers & other stakeholders to ensure smooth operation of the plant.
Heading Maintenance & Project department for the state of the art, 50 KMT/annum, lubricant blending plant & mentoring three members. ( Direct Reports / Team : 3 /10)
Led the Brownfield project from an initial capacity of 25 to 50 KMT/year with immaculate safety record of ZERO Loss Time Injury. Responsible for coordination with TOTAL Paris, regulatory bodies & inspection agencies.
Obtained up-to 25% discount for CAPEX activities, managing team of multiple designers, design reviewers, contractors, consultants & internal departments for ensuring successful & timely closure of project both technically & financially.
Head of Technical Procurement & Committee Member for proposing OPEX Budget.
Effectively negotiating Maintenance Contracts & building in-house expertise contributed to reduced maintenance cost to OPEX from 7% to 2.5% & utilities cost by 20%.
Benchmarked operational performance against Group and International Standards, achieved highest maintenance KPI within TOTAL Group (Uptime of critical equipment > 99.50%). Initiated & managed improvement programs, completed more than 40 improvement tasks/year hence creating a continuous improvement culture.
Coaching and training new recruits for proper, efficient operation of automated machinery and equipment.
Implemented Group Business Guidelines, Total Productive Maintenance, Reliability Centered Maintenance & ISO systems for Quality, Environment & occupational health & safety.
Fruitfully conducted numerous financial, insurance, specialist & regulatory audits. Certified Internal Auditor for IMS (ISO 9001:2015, ISO 14001:2015 & OSHA 18001).
Serving as Incident controller for Crisis Management Cell (CMC) & Team Leader for Emergency Response Team.
Water & Power Systems Technology (WAPStech), Saudi Arabia
•Handled team of more than 100 members comprising of different disciplines.
Having experience of working with ARAMCO, SABIC & their affiliates on Turnkey, Shutdown and Maintenance projects in Oil & Gas, Petrochemical, Water Treatment & Float Glass industrial facilities.
•Handled multiple projects under extreme conditions & technically demanding environment, accountable for all areas of Project Management.
•Led E & I team & completed greenfield project of construction of Obeikan Float Glass plant(Yanbu, KSA) with capacity of 800 MT/Day, in record 10 months (2 M$)
•Led MEI team in timely execution of greenfield project of Waste Water Treatment Plant, MARAFIQ (Jubail, KSA) (1 M$)
•Led brownfield project of overhauling RO plant in Saline Water Corporation (Jubail, KSA), World largest saline water handling plant (200 K$)
•Led numerous brownfield projects in TASNEE Petrochemical Complex, Saudi Mining Company (MAADEN) & Aramco Shell Refinery (SASREF) (Ranging from 100K -500K $)
Bahria University, Pakistan
•In-charge of DSP & Networks Lab, taught Digital Signal & Image Processing, Advanced Control Systems, Data Communications & Computer Networks.
•Head of Internship program (2009) & supervised semester projects for bachelor degree students.