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Ahmed Salem El-Taleb

**** ****** **** **** ********, OH 43220 614-***-**** acuq10@r.postjobfree.com Manufacturing / Quality / Reliability Engineer

Profile:

Advanced engineering education (PhD) and over 15 years of hands-on engineering experience in manufacturing, quality and process improvement. Key areas of experience are:-

Excellent analytical and innovative engineering skills

Design engineering skills in steel / polymer molding process

Process improvement and quality management experience

Expert in using quality tools like SPC, FMEA, FTA, QFD, DOE, Root Cause Analysis, Cause & Effect Diagram

(Fish Bone), Process Mapping, Pareto Analysis, and PDPC

Continuous Improvement techniques using latest tools like six sigma, TQM, Kaizan, Kanban, PDSA, TOC, Reengineering, DMAIC, and Benchmarking.

Expert in process validation (i.e IQ, OQ, PQ, VP, QP, IQSR, VSR)

Risk analysis (pFMEA, dFMEA)

Experience in CAPA

Well versed with FDA CFRs

Experience in First Article Inspection and NCR management

Project Manager, planner, team player and leader Work Experience

ProcessValidation / Manufacturing Engineer 2013 to Present Zimmer Medical Inc. Warsaw, Indiana, USA

Zimmer Medical Inc. is the global leader in Orthopedic Implant devices. Working as Process Validation / Manufacturing Engineer in its headquarters at Warsaw, Indiana. Responsibilities include:

Process Validation i.e IQ, OQPQ, VP, QP, IQSR, VSR, pFMEA and work instructions preparation, execution & documentation.

Plan and execute process upgrade of Vitamin E (VE) blended Ultra-High Molecular Weight PolyEthylene (UHMWPE) compression molding Machine, Temperature mapping on platens and comparison was made using Kaye Validator.

Process Validation for Poly-Methyl Meth-Acrylate (PMMA) coating process of Tibia, Zimaloy Femoral and Segmental Stems with PMMA

Equipment and Software validation of CNC Machines with Tool Setters &Measuring Machine (e.g. CMM, Zoller).

PhD Studies in Industrial and System Engineering from Ohio State University 2009 to 2013 Company for Electrical Cables, Bou Atni, Benghazi, Libya May 2000 – Mar 2006 Sr. Manufacturing Engineer

Fabricated high voltage copper cables insulated with XLPE, galvanized steel tapes and wires as a mechanical protection, jacketed with different polymers such as PVC and PE.

Production was continuous operation (24/7) using a Continuous Vulcanization extrusion machine for XLPE high voltage power cables.

Produced up to 2400 telephone lines in one telephone cable, PE insulated, Petrol jelly used as protection, PVC jacketing.

Managed 300 employees (engineers, technicians, laborers). Oversight included production, plant maintenance, plant safety, production planning and quality testing labs.

Responsible for hiring, staffing positions, contract labor, performance evaluations, union negotiations. Served as expert on all machinery in plant.

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Sr. Quality Engineer May 1992 – May 2000

Reporting process schedules, long term planning and product development cycle to upper management. Performed quality control procedures through use of statistical techniques to identify necessary improvements and controls of power cable plants.

Process evaluation, Cp, Cpk, Cpm, VSM, and six sigma improvement.

Assisted in creating product specifications by evaluating customer needs. Interacted with clients to improve product quality to ensure customer satisfaction.

Maintained a safe work environment by following standard safety procedures.

Developing pFMEA & dFMEA of product.

Maintenance Planning Engineer for Petrochemical Plant May 1989 – May 1992 Sirte Oil Company, Brega - Libya

Recorded and reported on all Methanol Plant equipment and repairs. Planned, developed, implemented and maintained the Methanol Plant.

Coordinated machine replacements, staff schedules, and inventory.

Responsible for forecasting daily maintenance needs. Troubleshooting, repairing. Interacted with maintenance team as needed.

Education:

The Ohio State University, Columbus Ohio

PhD, Industrial and Systems Engineering From 2009 to 2013

Areas of study include: Design of precision parts, Microinjection molding process of polymer parts, Stress and strain analysis on deformable parts and Statistical modeling of process parameters.

Deferent designs of complex metal forming of Advance High Strength Steel AHSS parts and Bending Studies for automobile industry.

Garyounis University, Benghazi, Libya

M.S, Industrial and Manufacturing Systems Engineering from 2004 to 2006 B.S, Industrial and Manufacturing Systems Engineering from 1985 to 1989 Areas of study include:

Metal Forming processes, Cold Extrusion of Aluminum parts.

Deferent designs of complex Aluminum parts and Bending Studies and material properties.

Insulation extrusion of polymer on a copper electrical and phone cables including PVC, PE and Rubber.

Stress and strain analysis on metal formed parts and Statistical modeling of process multi-parameters.

ISE Coursework and Projects:

Design in Mechanical Engineering, SolidWorks design software and CAD/CAM Laboratory.

Computational Fluid Dynamics (CFD), Moldex3D software, Applications of Tribology.

Statistical quality control, FMEA, quality management systems, ISO9001 Training period.

Measurement systems, design of experimental techniques, Six Sigma.

Supply chain management (SCM).

Quality, Reliability, DOE, Engineering Economic analysis and Project Management

Applied finite element method, ANSYS software.

Design of Workplace Environments / Ergonomics.

Validation / Qualification Quality Management Course from Zimmer

Quality Tools for Root Cause Analysis Course from Zimmer

CAPA and QSR (Quality System Regulations) Course from Zimmer.

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