Area Engineer
Emirates Aluminium
مجموع سنوات الخبرة :37 years, 11 أشهر
TEAM: 4 Engineers, 17 Technicians and 35 direct supervised contract Employees
▫ Developed detailed specification of workshop equipment, Workshop layout, SOP, Service Level Agreement (SLA), Operating principles and management strategy for Central Mechanical workshop and Lifting Inspection services
▫ Reviewing Standard Operating Procedures (SOP) through Work Observation Techniques (WOT) and continuous follow up to close out recommendation
▫ Implementing continuous improvement on shop floor and approaching low cost management strategy by applying LEAN SIX SIGMA tools such as 5S, Visual Factory, Autonomous Maintenance through CLLTPM techniques, TPM, KAIZEN, Suggestion Scheme, WOT, Error Proofing method ( POKA-YOKE), A3 thinking, MUDA elimination, FMEA
▫ Preparation of annual budgets and established monitoring system to maintain unit cost as agreed in Strategy objectives
▫ Preparation annual strategy objectives for department and ensure that tactical and operational objectives are meeting strategy objectives through periodical audits and reviews
▫ Developed succession plan for Emirates nationals and training in progress to take active role
▫ Implemented cost effective management and Maintenance planning system through employing of contract labors, controlling system on outsourced jobs, controlling on planned jobs performance, Controlling on overtime, effective use of spares etc….
Select Accomplishments in LEAN MANAGEMENT
▫ Established first 5S in office and took role model for implementing office 5S in Emal
▫ Established 5S on shop floor and recognized first 5S competition award in Emal 2011
▫ Established pilot project for Visual management and Kaizen
▫ Established pilot project for Autonomous Maintenance as part of TPM
▫ Team Recognized best suggestion awards for the month of May and June 2011
▫ Awarded for “Best Lean Improvement Project 2011”
▫ EHS Suggestion presented in idea UK and Dubai Quality forum in year 2012
▫ Awarded “ 5S certification” to workshop and Lifting Inspection services in year 2013
▫ Cost of Repair for crust breaker reduced from 54% to 32.6% in two years and cycle time of repair reduced from 6 hrs to 3.5 man-hours per crust breaker through eliminating wastes (Muda)
(TIM P WOOD)
▫ Continuous Improvement project on crust breaker repair ( SDCA and PDCA cycle) presented to top management as “best practice”
Team: 20 Technicians and 5 Contract Employees
▫ Developed detailed specification of workshop equipment.
▫ Developed operating principles of Central Mechanical workshop.
▫ Developed Service Level Agreement with Various Internal Customers.
▫ Resources planning for the workshop (consumables, tools, materials, measuring instruments, etc).
▫ Involved in recruiting trades for Central Workshop.
▫ Developed utilization plan and coordinated with other team members to prepare training materials for workshop trades.
▫ Involved in preparing management strategies of Central Mechanical workshop.
▫ Introduced 5R system in Central Mechanical workshop.
▫ Developed SOP and Task list for Central Mechanical workshop.
▫ Carried out FMEA study and formulated the preventive maintenance frequency for workshop equipment.
▫ Prepared annual budget-2008 & 2009 for Central Mechanical Workshop.
▫ Involving and Developing scope of work (SOW) for various workshop activities.
▫ Coordinated with SCM and finalized all service contract
▫ Developing 5s strategy in central workshop including Mobile shop.
▫ Application of maintenance and materials planning through SAP - ECC 5.0 System.
Select Accomplishment
▫ Received letter of appreciation for implementing 5S and Good housekeeping standards in Central Mechanical
Workshop
▫ Involved and established two kaizen projects in Sohar Aluminium
Managed a team of 21 Technicians
▫ Involved in erection and commissioning of ALBA Line-5 expansion workshop
▫ Introduced procedures for the Workshop and Job flow for Technicians and employees.
▫ Prepared and implemented Job Safe Practice (JSP) for Machine Shop, Fitting Section, Hydraulic Section and Welding & Fabrication Section.
▫ Conducted monthly Safety Meetings and trained the employees for JSP; also undertook periodical Workshop Jobs’ Risk assessment (Identification, mitigation & JSP feedback).
▫ Coordinated with the Training Dept to plan Technical Training for Section Employees.
▫ Prepared annual and ongoing Employee performance assessment.
▫ Targeted training for Bahrainis to undertake higher responsibilities.
▫ Developed local spare part vendors for expensive spares.
▫ Evaluated, negotiated and awarded and Coordinated with external contractors for service job contracts.
▫ Had been responsible for the plant wide maintenance of Rotary and Hydraulic equipments.
▫ Worked on damage assessment, scrapping of unviable parts and triggering of procurement actions in SAP R/3.
▫ In-charge of preventive and Breakdown maintenance of overhead Cranes of 10T capacity.
▫ Planned Annual Material requirements and Purchases.
▫ Maintained equipment history as well as Daily job and materials planning in SAP R/3.
▫ Developed training plan and implemented for Bahrain nationals
Select Accomplishments
▫ Received gold card from department Manager for fabricating the blower locally and saving cost of US$6000/ blower
▫ Received letter of appreciation from CEO-ALBA for 100% attendance in 2006
▫ Received recognition letter from CEO - ALBA to contribute commissioning activities of the Line -5 within 77 safe days in 2005
▫ Received safety suggestion award to eliminate the hazard at work area in 2002
▫ Received letter of appreciation from CEO-ALBA for contributing to achieve 5000000 man hours without LTI
Team of 10 Mechanical Technicians.
* Planning of preventive Maintenance jobs and arranging resources
* Daily routine jobs and attending break down jobs based on production priority
* Initiative taken to introduce spares from local vendors
* Based on condition monitoring of equipment report, in coordination with production department to plan early maintenance (Proactive approach)
Team of 7 Mechanical Technicians.
* Planning of preventive Maintenance jobs and arranging resources
* Daily routine jobs and attending break down jobs based on production priority
* Initiative taken to introduce spares from local vendors
* Based on condition monitoring of equipment report, in coordination with production department to plan early maintenance (Proactive approach)
Maintenance of pumps, Compressors, Valves, Mechanical seals, Gear boxes, Heat exchangers etc...