Maintenance Manager
Sunbulah Group
Total des années d'expérience :16 years, 7 Mois
▪Strategically develop and envision project business case on a +5 year over year plan working on an extended longer hours and high level of collaboration to Technical & Manufacturing Director integrating product profitability value.
▪Spearheaded capital expense projects planning, budgeting, execution, completion, hand over, closure and capitalization with heavy visibility and full engagement in the shopfloor on a well-timed 100% completion rate in every project initiated.
▪Top catalyst of astonishing inhouse installation and commissioning of a fully automated pallet and glass preparation machines due to Covid-19 travel ban. Optimized 8 HC and raw material damages. NPV of 0.4 MMSR savings annually.
▪Engineered a full machine mechanization of tray/RSC carton and product formation on a delicate branding requirement that minimized 8HC and operational effectiveness on a favourable impact of 0.4 MMSR annually.
▪Streamlined final automation key structure on a high intense work around of a robotic palletizer integrating various conveying and spiral systems unifying all bottling lines to a centralized cutting-edge technology that lay forward a world class plant in the Kingdom of Saudi Arabia. Beneficial effect of 0.5 MMSR annually; optimized 9 HC, scraps and O&M repairs.
▪Prime mover of digitalization that outlined all programmable logic control (PLC) addresses and principal components. Creatively generated workable solutions from backend to stakeholders providing real time data enhancing decision-making.
▪Led a winning engineering sachet machine solution for a marketing launch confirmation of a one hand opening sachet that showcased exceptional technical adaptability and a a leap forward among competitors enabling product innovation.
▪Successfully completed a brown field mix proof process automation integrating a highly complex 400+ manual valves to a fully process automated solution enhancing stakeholders’ operational excellence, eradicating pipeline crystallizations and putting an end to mixing of products. NPV impact of 0.947 MMSR annually on a 2.5-year payback period.
▪Enforced 250 preventive maintenance plan and executions annually on a 100% adherence rate channelling a winning strategy of machine availability; mean time between failure magnification (1200 HRS) and a 5% YoY mean time to repair improvement.
▪Professionally designed and assembled a grid-tied solar PV array of 50kWp with a calculated 86, 400 kWh savings annually that enables the use of sustainable clean energy and carbon footprint reduction.
▪Integrated all equipment and utilities requirement for a new external warehouse on various chilled and ambient storage condition requirements. The successful completion provided continuous logistics operation, saved ~+1MM SR on annual operating expenses related to storage, losses, container, delivery and demurrages delay costs.
▪Proactively assisted RnD, technical packaging, and material planning departments by qualifying new materials and prototype products in the machines. Raised various capital projects for the jigs and fixtures, modular changeovers and moulds.
▪Administer vehicle and material handling equipment (MHE) management & repairs. Formulated capital expenditure replacements strategy plans ensuring logistics operational continuity 24x7.
▪Propelled numerous advanced machine overhauling with OEMs adding +5Y asset life. Acquired advanced trainings and game changer knowledge expertise. Managed all transportation, living accommodation and hospitality needs of service engineers.
▪Perfected the plant expansion journey working on greenfield and brownfield phases without any operational stoppage. Collaboratively worked with supply chain organization to mitigate business risk to carefully plan for various execution phases.
Awarded a plaque of recognition by the chairman of the board for the valuable contribution and commitment.
▪Championed full customization, engineering design and installation of a complete processing lines with a total capacity of 8000kg per hour fully equipped with state-of-the-art technology power electronics and high-class hygienic components that propelled business operation. Total accumulated acquisition value of 12.5 MM SR.
▪Pioneered a comprehensive full bottling line installation for hexagonal and square jars product. Actualized factory acceptance test, site acceptance test, commissioning, training until hand over and closure of the project. Applied technical mastery for O&M that successfully led to highest output the plant has ever achieved.
▪Attained on time demand (OTD) by hands on installation and commissioning of a complete bottling line tailored for round jars equipped with innovative technology. This achievement transcended a heavy reduction of 30x change overs per month.
▪Revamped preventive maintenance strategy by further establishing a Total Planned Maintenance (TPM). Developed advanced condition-based monitoring, calibration and non-destructive testing that accurately leveraged data logic techniques avoiding breakdown maintenance and enabling leaders to have control over the machine.
▪Established spare parts store well-equipped with critical and fast-moving spares that empowered the factory to run smoothly 24x7 while delivering inventory best practices at 100% SAP codification of 10, 000 parts on a store value of 1.8 MMSR.
▪Revived and PLC modernized two retired bottling gratifying change over dilemma. Engineered a well-designed conveying system adapting flexibility runs. Improved 3% filling dosing accuracy enriching product profitability.
▪Enhanced plant power factor from 0.79 to 0.99 thru installations of accumulated 500 kVAR capacitor banks that minimized electrical bill and resolved bill penalty from Saudi Electric Company on a cost savings of 0.12 MMSR annually.
▪Revolutionized maintenance best practice from a run to fail breakdown maintenance method to a world class maintenance. Established maintenance metrics and targets that led to mindset empowerment of maintenance activities.
▪Strategically pioneered an annual master preventive maintenance and overhauling plan that resulted into maintenance turnaround increasing machineries asset life +5Y, machine performance and quality rate.
▪Formulated maintenance organizational structure thru creations of a very well-versed job descriptions, R&R’s, magnificently detailed KPI’s, dense screening, filtering and hiring highly skilled competent maintenance team.
▪Accurately provided budget planning for maintenance expenses and critical spare parts adhering to an improved cash flow.
▪Collaborated in improving batch heating preparation time by installing shear technology improving 460, 000 kg YoY output.
▪Devised an online OEE monitoring and established machine data communication transfer accessible via IP address that strengthen leaders for key decision-making process and operational improvements.
▪Part of a triumphant professionals that expanded a 40MW Solar PV manufacturing plant to a massive 400MW capacity. Fortified engineering on installations, O&M of various photovoltaic power testing machines with ABB robotics integration.
▪Redesigned and elevated life span of flash generator (2, 750 USD per equipment) from 60k flashes to astonishing 300k flashes with an annual cost savings of 475k USD for 10 lines.
▪Energized with test stakeholders and overall equipment manufacturer (OEM) in revamping critical data acquisition test that supersized test capacity from 24 to 40 UPH.
▪Successfully passed statistical process control (SPC) six sigma level 6 for test process implementing DMAIC approach and has spearheaded tool lock down activities on a real time feedback automation.
Completed Academic Units (Candidate Q4-2024)