Engineer Maintenance

Bassam Malek, P.Eng.

Member of the Professional Engineers of Ontario

** ***** **** # ***, ******, ON N7T 7V2

226-***-****, ******.*****@*****.***

PROFILE

• A Professional Engineer with 15 years of experience in fast-paced manufacturing environments

• Certified Six Sigma (Green Belt) and Lean Manufacturing

• Strong leader with a proven ability to analyze and problem solve issues and concerns and implement

corrective actions that sustained machine uptime

• Proven communicator in both English and French, demonstrate interpersonal skills, excellent team

player, reliable, flexible, dynamic, persevering and determined to achieve objectives

• Excellent knowledge of Solid Edge, Kaizen, 5S, Total Productive System (TPM), Business Operating

System (BOS), SAP, OSHA, FDA, OEE and HACCP standards

PROFESSIONAL EXPERIENCE

Cabot Canada Ltd., Sarnia, ON 2011-Present

(Major supplier of Carbon black to tires manufactories in the world)

Maintenance and Reliability Manager

• Lead, coach and support a team consisting of a reliability engineer, a maintenance supervisor, a

scheduler/planner, 10 millwrights and five electricians who consistently meet performance expectations

• Establish and ensure the WO’s are completed and returned to the planner which reduces the re-work of

the planner and provides extra time to schedule and plan other tasks to the crew, improving efficiencies

• Prioritize the reliability engineer’s projects which leads to improve and enhance execution of top

projects and reduces overtime costs

• Initiate and schedule a monthly meeting with the finance manager, the maintenance supervisor, the

reliability engineer and the planner to update monthly spending resulting in better control of spending and

ensure all completed PO’s are closed by month end

• Introduce and implement the updating of all continuous improvement plans to all departments which

keeps all action items on track ensuring continuous improvement initiatives are consistently met

• Control the unplanned downtime and keep monthly shutdown on time by analyzing machine historic

and using advance technology such as vibration and oil analysis

• Coordinate all outside contractors related to maintenance and reliability projects

• Efficiently manage a budget of $1M ensuring continuous operations

Tenneco Automotive, Owen Sound, ON 2007-2011

(Major supplier of ride controls for GM and Ford mid-size trucks)

Maintenance Leader/Manager

• Enhanced 29 maintenance crew members’ performance through effective coaching and supervision

• Decreased overspending by maintaining the maintenance department annual and shutdown budget

• Utilized Six Sigma methods to identify the root causes of high amount of daily overdue PM’s and

implemented corrective actions that reduced the daily overdue PM’s from 120 to 20 within six months

saving the Company approximately $63K yearly by reducing the downtime

• Enforced all available new technologies to be used and all PM’s to be done properly and on time

improving machine availability and increasing the OEE (Overall Equipment Efficiency)

• Increased the maintenance crew performance and involvement by generating projects to be executed

as planned, on time and within budget

• Reduced downtime and increased equipment efficiency by identifying the machines causing the most

downtime in the Business Operations System and implementing corrective actions

Bassam Malek, P.Eng. Page 2

Maintenance Leader/Manager, continued

• Applied 5S standards in the maintenance department to organize the work areas and improve the

workplace environment

• Created a safer work environment reducing lost time accidents by eliminating safety hazards

• Designed tooling for machines so parts could be made in house and available any time reducing

replacement cost and downtime

• Saved the company approximately $20K yearly by reducing metal waste in the tubing department

using Six Sigma methodologies

Applied Extrusion Technologies (AET), Varennes, QC 2004-2007

(North American Organization providing flexible packaging, product labeling, consumer packaging to Coca-Cola, Pepsi

Cola, Gillette and many others)

Maintenance Supervisor

• Enforced the HACCP standards in the maintenance department by identifying noncompliance issues

for corrective action

• Optimized the maintenance department availability for the production line by hiring two additional

millwrights for better coverage and overtime cost reduction

• Followed-up on different projects, their progress and oversaw the general facility maintenance

Champlain Plastics Inc. (CPI), N.Y. U.S.A 2000-2004

(U.S. based organization with main product made by injection molding process – CPI is a major supplier of clothes

hanger to Sears and buttons to GAP)

Maintenance Engineering and Supervisor

• Created, wrote and implemented a log-out/tag out practice with the help of the setup crew and outside

consultant, leading to a reduction in incidents rates and insurance premiums

• Established a recycling and waste management program in compliance with environmental laws, that

led to a reduction in waste generating approximately $10K in revenue yearly

• Implemented preventive maintenance program for injection, compression, die-casting, and

all auxiliary equipment that increased machine uptime

PRIOR TO 2000

Canadian Broadcasting Corporation (CBC), Montreal, QC, Project Engineer

McGill University Health Center, Montreal, QC, Maintenance Engineer

EDUCATION AND TRAINING

École de Technologie Supérieure (E.T.S.), Université du Québec, Montréal, QC

Bachelor, Mechanical Engineering

Engel Canada, Guelph, ON

Maintenance Intensive Training

Chamber of Commerce, Plattsburg, NY

General Industrial Safety and Electrical Safety Training for OSHA

Tenneco, Michigan, USA

Tenneco Leadership program

Tenneco Six Sigma Green Belt certification

Tenneco Lean Manufacturing certification

Ergonomics Intensive Training

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