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Maintenance Manager

Cairo, Cairo Governorate, Egypt
7000 $
October 18, 2016

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**** **** ********* ****** – El-Mukattam, Cairo, Egypt.

Mobile: +2-010********

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Career Summary

Having 17 years of professional industrial experience in operation and maintenance fields plus 3 years in Oil / Gas field, the last 9 years being manager of production process engineering in LEONI Egypt, following 2 years as a manufacturing manager.

-- During my career in LEONI, I collected extensive experience in establishing, building up and managing maintenance and process engineering functions which supporting the production core process in the plant. Being expert supporting the global expansion for LEONI in eastern Europe plants (Romania & Serbia) also developed strong business and intercultural skills. My particular strength is the organizational, technological and logistical setup, management and optimization of global value chains which target competitiveness of plants cost rate.

-- The previous role in ABB was also about setting up a plant transferred completely from ABB Norway and installed in Egypt.

-- The first Job was in the biggest Egyptian Oil producer “GUPCO” in an offshore gas lift platform producing 55,000 barrels of oil daily that gives me a hand on experience in wide range of rotating equipment,

-- I also have good practical hands-on experience down to workshop and equipment level.

-- My managerial, technical and leadership skills were supported by prior 5 years of academic mechanical power engineering Studies at Cairo University @ 1994; the graduation project was related to cogeneration feasibility and combined cycle in

“Helwan” Power Station which supplies 400 MW to the grid. Education

B.Sc. Mechanical Power Engineering “July 1994” University : Cairo University Grade : Good High School “July 1989” School : El-Ibrahimia Grade : Very Good Professional Experience

Current Employer “ LEONI Wiring Systems “

From 3/2007 to current “ promotion” " Production Process Engineering Manager” From 5/2005 to 3/2007 “ promotion” “ Manufacturing Manager “ From 3/2003 to 5/2005 “ promotion” “ Senior Maintenance Engineer “ From 8/2000 to 2/2003 “ Maintenance Engineer “”

Subordinates 2 managers, 8 engineers, 120 skilled team leaders and technicians


Participate in plant objective setting; ensure that company policies, procedures and standard are in place.

Forecasting and submitting the yearly budget for CAPEX & OPEX for the department and control it with the finance team.

Drive the plant maintenance programs through planning approach and preventive/predictive methodologies.

Controls the operation of plant equipment with the cooperation with the production team to achieve company KPI.

Improves key performance indicators KPI’S for maintenance department.

Coordinates with quality team after equipment testing to ensure machine capability index Cmk is achieved.

Establishes a computerized maintenance management system (CMMS) using APIPRO software.

Implements programs to ensure plant cleanliness and optimization 5S, TPM, SMED.

Establishment, start-up and management CNC machining workshop through a complete CAD/CAM system for spare parts manufacturing.

Issue operating instructions, FMEA, care points and visual aids for all the equipment.

Monitors spares stock value, controls the consumption, ensuring the availability of spares for key equipment’s.

Supervises maintenance personnel to ensure the staff is adequately trained, equipped, utilized and motivated.

Conducts employee performance reviews based on achievement of their target.

Maintains safety, health, and environmental policies and procedures and enforce the safety programs. Achievement

Remarkable input in reducing the plant cost rate which enables the company to expand the foot print locally 8 times in 12 years increasing the standard hours to be around 0.5 million standard hours monthly instead of 0.5 million yearly, the total headcount increased from 1000 employee at year 2000 to be 5800 employee at year 2016.

Supervise the installation and operation for production lines in new LEONI plant in Serbia @ 2014 with a total investment 40 million euros that supplies to Jaguar & Land Rover plant in UK.

Keeping more than 95% of plant reliability with 94% production equipment availability – without P.M time-.

Increase the craft utilization percentage to be 90% by using effective maintenance planning tools in CMMS.

22% reduction in maintenance cost through advancing a complete CAD/CAM system to in-house manufacture some of the spare parts, tools, Jigs and supplies these parts to other LEONI sites abroad.

A proven track record in enhancing and implementing the Lean Manufacturing concept in plant sections by effective implementation of TPM ( Total Productive Maintenance ) & SMED ( single minute exchange of dies ), that results in increasing the OEE ( Overall Equipment Efficiency ) by 5%.

Drive 6 sigma and KATA projects to reduce the different kinds of waste in the production equipment.

Manage the introduction and smooth running for more than 40 projects from different German plants to Egypt. Previous Employer “ ABB “

From 4/1999 to 8/2000 “ Production Engineer “


• Full installation for the factory production lines, including testing, commissioning, capability studies, first release.

• Validate the MOM for the plant equipment’s; create the visual aids for operating instructions, FMEA, care points.

• Ensure process release a lean process flow, proper layout, necessary tools, and jigs for optimized process cells.

• Ensure a proper maintenance plans and necessary spares for production lines. First Employer

“Gulf of Suez Petroleum (GUPCO) “

From 3/1996 to 3/1999 “Shift Engineer at offshore gas lift platform (Turbine department) “ consists of 2*25 MW Gas Turbine driving 4 Turbo compressors Responsibilities:

• Carry out the operation of the platform through monitoring and analyzing the performance curves for the rotating M/C.

• Set, design and execute different maintenance and inspection programs for platform turbines and compressors.

• Condition based monitoring for the equipment parameters (e.g. pressure, temperature, flow rate, level, speed and vibration).

• Analyzes sudden faults and repairing malfunctions.

• Controls the spare parts stock to ensure the platform availability. Training Courses

“Preventive maintenance planning”. LEONI (UK)

“Total productive maintenance (TPM) “. LEONI (Germany)

“Computerized maintenance management systems CMMS using APIPRO software ". LEONI (Germany)

“Optimization of set up times and SMED “. LEONI (Germany)

“PLC Course in "maintaining and troubleshooting an SLC 500 systems using RSLogix 500 software". Allen Bradley (Egypt)

“Operation and production management “. Olympic (Egypt)

“Project management skills”. Olympic (Egypt)

“6 Sigma champion roll “. LEONI (Egypt)

“Creative thinking & problem Solving Skills “. SGS (Egypt)

“Effective delegation “. SGS (Egypt)

“Gas turbine operation, performance and maintenance”. Mobil Oil (Egypt)

“Gas processing course“ GUPCO (Egypt)

“Attend the - 6 months - commissioning and start-up period for Dahshour pumping station this consists of 6 gas turbines type Nouvopignone driving 6 centrifugal same type pumps. “ SUMED (Egypt)

Additional Info

Perfect computer user at Microsoft office package, Automation studio and Solid works. English language: Excellent

Date of Birth: 27 June 1971.

Military service: completed at 12/1995.

Married with 2 children, References are available upon request.

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