Quality Control & Lboratory Manager (Chemist)

Mohamed Hamed Mowafy

Contact: +2-011******** - 010********) E-mail: *********@*****.***

Skype: asec.engineer

https://www.linkedin.com/in/mohamed-mwafy-2a8b8661/

Preferred Location: Kuwait /Saudi / Oman / U.A.E. / Bahrain / Qatar / Africa / Euro /USA

Cement Quality Professional – Quality Manager

Offering a sterling experience of +10 years; seeking a challenging in an organization that provides me ample opportunity to explore & excel as Leader / Manager QC in the domain of Cement Industry

PROFILE

I had more than +11 years of experience in cement industry, over the last 5 years I was work as Quality Manager, managing projects, plant operation, Lead & implement QMS, and leading auditing for ISO Standards in several plants in Egypt, Jordan & Iraq.

Direct ownership and responsibility for all Quality and the management of Quality.

Controlled and reported all the changes to the process relating to quality.

Manage the quality systems (ISO 9001) and laboratory systems to maintain the highest product quality standards to meet and maintain the product certifications and ensure consistency and accuracy of the laboratory.

Collaborate with Quality short and long-term strategy planning, project management, contracts and procurement, data analysis, claims adjudication and business writing.

Coordinate with production and customer service/sales to control and improve the quality level of our products.

Competent, diligent & result oriented professional with an experience of 10 years in handling sophisticated instruments, providing effective quality control at various cement plants in Egypt and Middle East. Currently spearheading as Q.C Supervisor and Management Representative - QMS & EMS with M/s. Aalborg Cement Company, Cementir holding.

Ability to implement chemical analysis & industrial process control of the product with careful & sophisticated quality control measures in compliance to the specified standards; excellence in ASTM, BS, EN, API, SAUDI & GSO Standards and specifications for the products White cement, OPC, SRC, FC, PPC, Masonry Cement and GGBFS.

Formulate and drive the development and implementation of the Company’s product quality program

Well versed in conceptualizing and implementing operational strategies for the quality function by carrying out quality planning to confirm the organizational QA/QC requirements. Successful in implementing day-to-day activities through SAP successfully for PP & QM module

Effective team leader, trainer and motivator with fine-tuned analytical and troubleshooting skills with excellent verbal and written communication skills.

Summary of Skills

Holding Licenses for configuration and protecting radioactive sources as X-ray instruments (IAEA).

Lead Auditing for QMS process according to ISO standards (IRCA).

Direct ownership and responsibility for all Quality and the management of Quality. All changes to the process relating to quality will be controlled and reported directly through the Quality department on the authority of the Quality Manager.

To manage the quality systems (ISO 9001) and laboratory systems to maintain the highest product quality standards to meet and maintain the product certifications and ensure consistency and accuracy of the laboratory.

Shared with Lafarge in Consultant to increase productivity of ALQAIM cement plant-IRAQ (from Dec., 2012).

Working with FLS team in commission 2nd Sinai Cement Line (2009).

IQCP member (International Quality & Productivity centre)

Implementation and maintenance of ISO 9001.

Involvement in Continuous Improvement techniques.

Management of cement laboratories, sampling and chemical analysis techniques.

Holding ICDL.

Holding Driving License.

Core Competencies:

Plant Supervision / Management Quality Assurance & Control Process Improvement Strategic Planning HSE/Safety Management Crisis Management Laboratory Management Testing & Inspection Research & Analysis Documentation/MIS Team Management Resource Management Training & Development Liaison & Coordination R & D optimisation Presentation Skills Influencing skills .

Professional Achievements:

I was able to reduce the cost by developing suitable mix design of raw material and fuel this resulted in decreased heat consumption and power saving of approximately 14 EGP/ ton.

I was able to reduce cost of grinding clinker by enhancing Clk/Cem Ratio according to EN standards.

Implement & maintain QMS and get ISO 9001 & CE Mark in 1 year.

Consume & Recycled of Historical bad quality clinker (about 200K ton) as additives with maintain the high quality cement competition in 1.5 year (30% of annual plant production).

Improve the process and quality of AlQaim cement which lead to increase sales percentage.

Ability to analyze and resolve customer complaints and the appropriate response and prevent recurrence later, Developing the policy of quality control to comply with the modern standards

Prepared a proposal of a new product and conducted many trials of Masonry Cement in lab ball mill and conducted tests which confirm to the regulated EN std. requirements and this product has received approval of the management and the sales was growth steadily and finding new markets for the products that we create.

Estimate Raw Mix design and Conducted many raw mix experiments in the lab with new iron source materials to obtain the good quality clinker.

Brought reduction in chemical consumption by 15% of the year by year doing the proper way of the testing by the chemists, by providing instructions of effective analytical skills.

Current capabilities:

1- Safety

Ensure compliance with the relevant statutory legislation and internal company Safety, Health & environmental standards

Communicate clearly on information relating to potentially dangerous, Hazards’ and near miss situations wherever in the plant and get confirmation they are correctly understood.

Check that chemicals & physical testing is correctly handled.

Analyze risk of sampling points & make sure they are correctly addressed.

2- Quality Control

Comply with product specifications according to Client contract agreement & specification stipulated in the agreement.

Ensure that raw materials provided by the Client are within specifications as stipulated in the contract agreement.

Develop/Design & implement the relevant quality control plans.

Follow-up on daily basis the compliance with these plans in order to guarantee the quality of the product ready to be dispatched.

Define & implement the short, medium, & long term strategies to meet plant product specifications (official standard, market objective & operational targets).

Coordinate Quality department objective and targets.

Maintain product quality in the market and standards requirements.

To assure that supplier surveillance activities affecting product quality and customer satisfaction are effectively developed, controlled, monitored and reported.

3- Quality Assurance

Coordinate, Manage and maintain the plant Quality Management System (QMS) and laboratory management systems e.g. ISO9001.

Monitor & analyze the quality of products on daily basis & take all appropriate actions to ensure that Client/customers do not receive the product out of specification product.

Planning and execution of quality assurance, quality control and inspection activities as they relate to project (contracts) order execution.

Define quality objectives for internal products.

Analyze specific risks regarding quality. Implement preventative actions when necessary.

Lead RCA in case of quality incident.

Follow & implement the evolution of product official standards.

Work closely with the Production Manager and Production Coach to ensure consistent quality operating standards are set and maintained.

Establish, develop, implement and maintain the Quality Control Department procedures to manage Quality control of raw materials, raw mix, clinker and cement.

Coordinate the quality control activities to ensure optimum production and cost levels

Monitor and assure the physical and chemical test results of Raw materials, in process products and finished cement for conformance to plant and regulatory specifications

Keep the Plant Management Team fully informed of quality performance and issues.

Ensure laboratory performance and efficiency is maintained at the highest level.

4- Continuous Improvement

Develop and implement department continuous improvement program.

Analyze on a regular basis the performance level of existing products. Drive improvements in availability and stability of the manufacturing process for producing quality.

Contribute to the design, acceptance & integration of new equipment & installations taking into account the quality of products.

Lead process when new products are being developed by doing industrial tests and analyze results.

Evaluate impacts of the use of cementitious, raw materials and process measures to prevent possible risks of the finished products.

Contribute to global optimization of the cash cost in terms of quality aspects (clinker grinding, cement formulation, etc.)

5- Budget

Identity in the plant any location where there could be some improvements in terms of quality.

Participate in the plant budgeting process in the form of quality contract.

Set and control department budget

6-Performance Criteria

Effective implementation of IMS & QMS

Compliance with product quality standards

Laboratory accuracy index.

Root Cause Analysis (RCA) carried out in case of quality incident.

Professional work history:

I.Current Job : Heidelberg cement – Aalborg Portland group -ASEC TM

Sinai white plant

From 1 March 2016 to date

Quality & Laboratories Manager (Chief)

Plant description: The plant has two production lines (FLsmidth design) Produced 3000 TPD of white clinker containing 2 Atox Mill 25, 4 stage preheater and in-line calciner(ILC) and two tube cement mills.

Products: White cement (CEM I 52.5 R, CEM I 52.5N, CEM II/B-LL 42.5R, CEM II/B-LL 42.5N, CEM II/B-LL 32.5 R),

Masonry Cement (MC 12.5, MC 12.5X), Grey OPC (CEM I 42.5 N, CEM I 52.5 N).

II.Company : ASEC-Al-Minya Cement- ASEC- Holding

From April 2014 to 29 Feb 2016

Quality & Laboratories Section Manager

Plant description: The plant has one production lines (FLsmidth design) Produced 6000 TPD of clinker (OPC & SRC) containing Atox Mill 50, 5 stage preheater and in-line calciner(ILC) and two tube cement mills.

Products: Ordinary Portland Cement (CEM I 42.5 N, CEM I 52.5N), Sulphate resistance cement (CEMI-SR , CEMI-SR , CEMI-LH).

III.Company : Lafarge Cement -AlQaim Plant – IRAQ

From 1 Dec 2012 to 31 March 2014

Quality leader of technical support team (consultant)

Plant description: The plant has one production line (Romanian) Produced 3000 TPD of clinker (SRC) containing 2 tube Mills, 5 double stage preheater and two tube cement mills.

Products: Sulphate Resistance Cement (CEMI-SR ).

IV.Company : Arab Swiss engineering company

From April 2007 to Nov 2012

Industrial senior chemist

Scope of work:

ASEC is an engineering company that works in the field of cement industry as a consultant of erection technical assistance for maintenance, operation and total management for cement factories

PROFESSIONAL EXPERIENCE

M/s. Heidelberg Cement- Sinai White plant, ASEC T.M. Since, March. 2016

Quality Manager - QMS & EMS

Key responsibilities:

Carry out quality planning functions, assuring that supplier procedures, product, and data will comply with applicable specifications and customer expectations.

Responsible to set-up internal Quality Specifications for Raw materials, In-process materials and Finished Products; reporting to the Plant manager.

Support External Customers through Marketing Department to satisfy their needs by Ensure the produced Cement meets the Customer’s requirement and resolving problems related to Quality.

Preparing ISO & CE projects and obtain them within 1 year at the plant.

Administrator of technical follow-up and quality control- lab. Department.

Interpret and analyse supplier data and assist other departments (i.e. Engineering) in determining impact to quality.

Interface with various internal and external personnel to investigate causes of non-conformances, minimize cost of quality, and strive for continuous improvement.

Develop and assist others in the development of procedures and working instructions.

Contribute to overall cost reduction/avoidance through participation in the internal corrective and preventive action system.

Maintain a positive working relationship with all internal and external contacts.

Chemical & physical analysis of raw materials to cement.

Preparation of mix piles and limestone piles as per requirements.

Preparation of raw mix design.

Calibration of Blaine apparatus by mercury displacement method.

Checking drift correction of XRF regularly.

Maintain raw mix hourly using XRF.

XRF analysis of raw mix, clinker, cement etc.

Schedule and direct supplier surveillance activities, ensuring compliance with applicable requirements, while working within budgetary constraints.

Manage timely collection and distribution of inspection reports and product data, as required by code, standard, or specification.

Evaluate inspection reports and assist in the development of remedial action plans to ensure conformance to specifications and standards.

Checking calorific value of HFO using bomb Calorimeter

Supervising and optimizing the activities of quality control functions for the production of OPC, SRC, FC, PPC, Masonry Cement, Oil well cement & GGBFS.

Monitoring, supervising and controlling of QC activities right from receipt of raw materials to finished products; knowledge of Physical & Chemical Testing of cement as per BS EN, ASTM, SASO & GSO Standards etc.

Carrying out the raw mix burnability studies with different raw materials and its proportions to study the material suitability for clinker manufacturing; handling optimisation of fuel mix for better production.

Maintaining coordination with the process department for producing better quality clinker and smooth operation of Kiln.

Involved in day-to-day monitoring of the results data. Holding close meetings with Lab Chief & Plant director for taking the corrective actions if any quality deviations to improve the better quality of the product.

Handled preparation of Monthly Test Certificate of finished products (Cements) and issued to the customers / clients; possess thorough knowledge of Physical and Chemical Analysis of finished product (Cement) as per the Applicable standards.. Reported to the Lab Chief.

Looking after the implementation of various techniques for improving the product performance along with reduction of main raw material for cost savings. (Eg. Evaluating different sources of Slag to reduce Raw material cost)

Handling preparation of shift schedule for all the lab staffs, technicians and allocating man power required for the work

Preparing daily, monthly & yearly quality reports of Cement & Raw materials with trend chart.

Preparing annual department budget with power point for presentation.

Organised calibration of lab equipments such as X-Ray Lab, Chemical Lab & Physical Lab from time to time by Internal Support Groups as well as outside Contractors.

Responsible to manage the supervision of shift employees to ensure an uninterrupted production while ensuring quality and safety. Accountable for directing, leading and motivating workforce; imparting continuous on job training for accomplishing greater operational effectiveness/ efficiency.

Constantly working on succession planning of the workforce, shift management activities, appraising the member’s performance & providing feedback. Resolving interpersonal issues & working towards a harmonious work environment.

Adhering to ISO 9001:2015 Quality Standards and ISO 14001:2004 Environmental Standards; maintaining all related documents.

Accountable for contributing to the reformulation, development, maintenance and enhancement of products through planning, executing and analysis of experiments with clear and accurate results demonstrating knowledge of chemicals and raw materials.

M/s. Asec-Alminya Cement. April. 2014 – Mar. 2016

Q.C Section Manager and Management Representative - QMS & EMS

M/s. Lafarge Cement - AlQaim Plant – IRAQ Dec. 2012 – Mar. 2014

Quality leader of technical support team (consultant) and Management Representative - QMS & EMS

M/S. Sinai White cement, Egypt Aug. 2009 – Nov. 2012

Senior Chemist - Q.C

Handled preparation of Monthly Test Certificate of finished products (Cements) and issued to the customers / clients; possess thorough knowledge of Physical and Chemical Analysis of finished product (Cement) as per the Applicable standards... Reported to the QC Manager.

Handling preparation of shift schedule for all the lab staffs, technicians and allocating man power required for the work

Managed SAP system for generating data & information. Prepared annual departmental budget by power point presentation & preparation of raw mix design.

Organised calibration of lab equipments such as X-Ray Lab, Chemical Lab & Physical Lab from time to time by Internal Support Groups as well as outside Contractors.

Managed Chemical Analysis of Raw materials, Semi finished product (Clinker), and finished product (Cement) by conventional as well as EDTA method.

Hands-on-experience in Proximate and ultimate analysis of coal & Pet coke; experienced in heat of hydration analysis, sulphide sulphur analysis, LECO sulphur carbon analysis etc.

Experienced in oil well cement testing as per API standards.

M/s Sinai White cement, Egypt April 2007 – Jul. 2009

Lab Chemist - Q.C

Managed Chemical Analysis of Raw materials, Semi finished product (Clinker), and finished product (Cement) by conventional as well as EDTA method.

Prepared work schedules and progress reporting to upper management; prepared periodic reports that focus on key business areas and analyze options on improvements. Reported to P & QC Head.

Managed complete quality assurance operations in line with the statutory requirements. Ensured implementation of quality assurance methods & took appropriate quality measures including preparation/ maintenance of necessary documents and conducting audits to ensure compliance with standards.

Conducted analysis of quality aspects, safety control and implemented strict adherence to safety measures & techniques, defects prevention, quality planning and customer satisfaction assurance.

Maintained records and documentation before and after conducting analysis.

ACADEMIC & PROFESSIONAL CREDENTIALS

B. Sc. – Chemistry (Organic and Inorganic Chemistry), 2006 Mansoura University, Egypt; 73%

Post graduate diploma – Analytical Chemistry, 2007 Mnoufia University, Egypt; 93%

Computer Proficiency: MS-Office, MIS, SAP & Internet.

Trainings Undergone:

Lead Auditing according to ISO 9001:2015 - 2018 (International register of certificate Auditors).

Use of Radiation sources/materials and radiation protection license 2017 (Egyptian Atomic Energy Authority).

Project Management for Managers 2016 (Knowledge Academy).

Mini MBA 2015. (Knowledge Academy).

Arbitration of investment disputes and drafting contracts program 2015 (League of Arab state).

Stress and conflict management 2014 (Knowledge Academy).

Quality Assurance in Cement industry (QA 2012) (ASEC Academy).

ASEC Cement Manufacturing Course (ACMC 2011) (ASEC Academy).

X-Ray Using, Configuration and protection Course 2010 (Thermo-MESCA).

CCR Operator Course 2010 (ASEC Academy).

Raw materials for cement industry course 2009 (ASEC Academy).

QCX Using and configuration 2009 (FLsmidth).

Training in quality control department on physical, Chemical, and X-ray lab tests.

Undergone training of QMS Internal Audit Course.

Interpersonal & Management skills:

Communication and negotiation skills.

Experience in dealing with Suppliers & customers.

Work under pressure.

Leading & Coaching Skills.

Time and stress management.

Self-motivated and able to motivate others.

Presentation Skills

Project Management & Planning Skills

Influencing skills.

Attention to detail and analytical data

Ability to communicate with people at all levels

People Management Skills

Personal data

Date of Birth : 8th Dec. 1984 (Male, Married).

Permanent Address : Cairo, Egypt.

Passport Number : (Egyptian) A21408185, valid up to 19.11.2024.

Languages Known : English, Arabic, and French.

Reference : Available on request.

Notice Period : > 2 weeks

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