Plant Operations and Project Manager
WR Grace
Total years of experience :24 years, 7 Months
• Plant Operations and Project Manager for Dammam and Jeddah
• Site S&OP Leader for driving business, Operations, Supply Chain and Product Development
• Planning all production activities on daily, weekly and monthly basis ensuring all major Plant KPIs are met.
• Preparing and implementation of annual Operating plans for CapEx projects, Factory Admin expenses, Manpower and Inventory on-hand.
• Managing major engineering new/ expansion projects of the Company from feasibility/ budgeting till completion.
• Preparing the timescales, costs and resources needed for new Projects.
• Drawing up a detailed plan and schedule for how to achieve each stage of the project
• Working closely with the Engineering Team to prepare all P&IDs, PFD and equipments design.
• Building strong relationships with existing Suppliers and source for new Raw Material Suppliers with high, consistent and competitive pricing.
• Developing Demand and Supply Plans for Raw materials making sure availability of all Raw Materials
• Developing and implementation of processes Standard Operating Procedures (SOPs)
• Preparing comprehensive Training Annual needs, developing Training calendar based on this and documenting training effectiveness
• Responsible for implementing Company’s EHS procedures and ensuring zero recordable incident environment
My Achievements:
• Increases in production yield and output, worker productivity, and other performance measurements
• Reductions in operating costs and overhead expenses
• Design, set-up, and start-up of new manufacturing facilities and production lines in Dammam and Jeddah
• Engineering/design of new processes and their positive financial impact
• Improvements in revenues, EBITDA, and other financial measurements through achieving Operations excellence
• Completing external EHS Compliance Audit with just one level 3 findings
• Completion of 2 major Projects worth $4M to develop a Grace new manufacturing facility in Western Region right from ground field till handing over and obtaining all required Governmental permits
• Responsibilities involved troubleshooting and maintenance of high tech. CNC/ NC machines.
• Develop strategies to switch over to total productive maintenance (TPM) and Reliability centered maintenance (RCM).
• Excellent maintenance experience of Diesel generators (500KVA - 1000 KVA) and industrial/ diesel compressors.
• Cost control of relevant engineering cost centers, and assigned project spending.
• Develop, promote and achieve a positive and productive team atmosphere within the maintenance group while working closely with QA, Production, Engineering and Tooling departments to establish common priorities, objectives and goals.
• Direct hand-on experience with in different robotic arms design/development and related softwares such as C/C++, Visual studio, AutoCAD, ERP etc
My achievements
• Design, set-up, and start-up of new manufacturing facilities and production lines
• Seamless introduction of new products into existing manufacturing plants and favorable financial results
Worked as an Assistant Plant Manager/ Maintenance Manager at Lefebvre Engineering FZC, Sharjah UAE with extended responsibilities of plant management.
• Direct and coordinate plant operations within company policies and procedures.
• Responsible for plant production goals.
• Coordinate with department heads to ensure coordination of purchasing, production, and shipping.
• Schedule and conduct plant meetings. Direct and coordinate manufacturing, construction, installation, maintenance, support, documentation, and testing activities to ensure compliance with specifications, codes, and customer requirements.
• Develop, co-ordinate and implement shutdown, preventative and predictive maintenance schedules
• Co-ordination of in-house trades and outsourced contractors to maintain/improve facility compressed air, cooling and electrical power.
• Developing the proper control procedures for maintenance such as work orders, work schedules, equipment listing, and machinery.
• Responsibilities also involved the installation/Commissioning/ troubleshooting and maintenance of high tech. CNC/ NC machines
Achievements
• Set up of 1200SqM expansion Plant including
• Reductions in operating costs and overhead expenses
• Major Conflicts resolution with the customers
• To carry out and oversee machines’ design and manufacturing process.
• To conduct preventive, predictive and breakdown maintenance of overall plant’s machines and equipments.
• Co-ordinate and plan repairs for weekends and shutdowns
• To provide technical erection/installation services for different oil & gas companies in China.
• Direct a team of 15 maintenance team to support production on a daily basis.
• To conduct preventive, predictive and breakdown maintenance of overall plant’s high tech CNC/ NC/ Welding/ fabrication machines and equipments.
• Co-ordinate and plan repairs for weekends and shutdowns
• Promote and implement continuous improvement initiatives
• Ensure the timely completion of preventative and predictive maintenance work orders
I have published 7 research articles in various well reputed journals (Elesvier, Springer, IEEE etc) as well presented my work in different conferences. I have been a reviewer of 2 international journals.
3 Merit certificates in Ist, 3rd and last term.
