Mechanical Engineer, CMM, Master's in Total Quality Management

Kamran Zahid Ali

Mechanical Maintenance, Reliability, and Quality Engineer

+1-732-***-**** ******************@*****.*** Linkedin/kamran-zahid-ali-mechanical-engineer-ms-tqm-cmm-83231b46/ Summary of Experience

Accomplished Mechanical Engineer with over 25 years of expertise in Equipment maintenance/reliability, Engineering production & Quality management. Demonstrated proficiency in Kaizen, Lean methodologies, Six Sigma, and FMEA. Skilled in project planning, scheduling and quality assurance on large industrial projects. Strong background in team leadership, process optimization, and safety improvements. Experienced in utilizing MS Office tools, project control management systems

(including CMMS/SAP), and data tracking/reporting tools to support project documentation. Skilled at coordinating design reviews, preparing reports, attending high-level meetings, and tracking project milestones. Excellent communication skills with proven ability to work independently and support project managers on large, complex projects. Experience

Manager Mechanical ITV Dec 2020 – Aug 2024

DP World Karachi / Qasim International Container Terminal QICT, Pakistan o Maintenance of 84 tractor-trolley ITV fleet with 100% availability/reliability/MMBF/MTBF alongside 50% reduction in fuel/TEU for 4 years. ITV engines ran doubled before requiring top overhaul as specified by OEM. o Resolved warranty issues of 64 New ITVs (Cummins 2019) with OEM Terberg to eliminate critical defects. o Diagnosed engine oil consumption through Root Cause Analysis (RCA) and eliminated it in all Cummins engines. o Enhanced safety and workflow through Lean methodologies/Kaizen-driven improvements and budget optimization for spare parts.

o Implemented Condition-Based Maintenance (CBM) techniques resulting in a 40% reduced maintenance budget. o Implemented a failure reporting and corrective action system (FRACAS), leading to a 10% reduction in recurring issues within the first year.

o Proposed EV shuttles for terminal & Pilot project comprising 4 EV shuttles 12 passengers along with 3 fast charging stations at planned locations with maintenance backup was approved from DP World head office in UAE. o Successful Pilot project to reduce operator fatigue through virtual monitoring alerts & incorporating vehicle telematics to optimize fuel efficiency.

o Implemented crack detection predictive maintenance program using vibration analysis and infrared thermography, resulting in unscheduled downtime of critical equipment and saving maintenance costs up to $50,000. o Introduced 4-year & 8-year PM plans using CMMS data to predict failures. o Successfully revitalized legacy mobile equipment thereby hiring of contract forklift was reduced by 30%. o Installation of high-resolution cameras to reduce rubber tire gantry operator fatigue was proposed/implemented. o Led training initiatives to improve staff skills, work ethics, and HSE culture. o Improved shop layout with improvised tools & fixtures developed in-house reducing 40% manhours. o Designed service facility for ITVs at 28-acre new Berth Buildup Area to be functional in 2025. Unit Manager Motor Vehicle Shop Feb 2018 – Dec 2020 FFBL Plant Site, Pakistan

o Managed operations/maintenance of plant mobile equipment & machinery including Semi-trucks & tankers for Phosphoric Acid, 25 & 60-ton wheeled Cranes, and Skid steer loaders engaged in fertilizer production. o Utilized Root Cause Analysis (RCA) to diagnose coupling failure resulting in zero occurrence during plant operation. o Developed and executed a comprehensive training program for Apprentices using diagnostic scanners with software tools, increasing team efficiency by 25%.

o Collaborated with OEMs to upgrade mobile crane equipment load/position faulty display replacing wire sensors technology with IoT-based monitoring systems to improve real-time display to ease crane operation. o Cost reduction through Suspension Air Bellows foundation modification in two models of P2O5 acid tankers. o 10% reduction in inventory through adopting interchangeable parts criteria. o 100 % Safe rigging operation of heat exchanger and pressure vessel replacements during Plant turn around. o Revitalize critical plant mobile equipment & machinery resulting in self-sustenance as well as a 35% reduction in rental equipment during plant annual turn-around.

o Trained Sub-engineer & Supervisor for QC inspections and implemented QA in the maintenance process. Technical Training Officer Aug 2014 – July 2016

EME Centre, Quetta, Pakistan

o Served as Technical Training Officer for a 6-month Electrical & Mechanical Engineers course. o Administered training of 850 Electrician/Mechanic staff with a team of 60 Technical & 75 Sports instructors. o Advisor to student Projects: Revitalize Engine Dynamometer, Develop test bench for EFI injectors & Rebuilding Accident damage Truck Toyota FJ-70 RKR.

o Prepare system-specific training modules for technicians to qualify as master trainers for EME units. Manager Maintenance, Engineering Production & Quality Management Oct 1994 – Oct 2017 Rebuild Workshops for Logistics Fleet and Industrial Equipment/Machinery, Pakistan o Maintenance and rebuilding of logistics fleet, industrial equipment & machinery. o Improved processes through PERT/CPM to enhance production output and quality. o Develop cross-functional teams to enable human resources for multi-tasking. o Led 100 % safe crane recovery operations, optimized material procurement, and conducted operational fitness inspections of EME equipment.

o Led Kaizen projects such as fire pump rebuild, vehicle dynamometer revitalization, and test bench development for Turbochargers and EFI injectors.

o Applied FMEA and SPC tools to eliminate engine defects, lead vehicle retrofits, and improve team efficiency. o Improved shop layout, revamped Engine shop, and established Quality Cell at EME Base Workshop Facility. Senior Inspection Officer Aug 2006 – July 2009

Industrial Production Facility, Pakistan

o Quality assurance inspections at all production stages. o Product qualifying OEM service life test standard with local material production. o Conducted technical trials, defect investigations, and implemented Six Sigma to minimize process wastage. o Coordinated with government and research departments for product development. EDUCATION

University of the Punjab, Lahore 2005 –2006

Masters in Total Quality Management

Project: Quality Management System in Field Workshop University of Engineering and Technology UET Lahore 1990– 1993 Bachelor of Science in Mechanical Engineering with Honors, Award: Silver Medal Project: Design & Development of Electric Trolley

SKILLS

Technical:

Process Capability Enhancement tools: Statistical Process Control, PERT/CPM, Total Quality Management; Lean methodologies Maintenance & Reliability Techniques: Root Cause Analysis, Failure Modes and Effects Analysis (FMEA), Predictive Maintenance, Reliability-Centered Maintenance (RCM), Total Productive Maintenance (TPM), Six Sigma Data Analysis: Data Collection, Data Interpretation, Statistical Analysis Production Engineering Projects: Equipment modifications/trials, process layout, budget optimization, wastage control, risk analysis. Diagnosis/Troubleshooting: Turbo diesel engine, transmission, driveline, Air and Hydraulic Systems Mechanical Engineering Tools: AutoCAD, SolidWorks (learning) Software tools: MS Office, SAP, Maximo, Power BI

Administrative:

Organizational structure transformation for productivity & efficiency improvement Security framework establishment by developing SOPs & implementing safety protocols Human resource development through motivational leadership Excellence in teamwork through cross-functional team potential development OTHER

Certifications: Certified Maintenance Manager CMM, Fundamentals of Terminal Operations FTO Certifications: Professional Engineer (PE) License Projects: Enhanced rebuild engine production by more than 200% as a result of engine rebuild shop revamping for Euro engines giving it an improved layout and QC/QA stages new test stands. Developed 4- & 8- year PM plan for equipment predictive maintenance based on data analysis leading to 50% reduction in breakdowns.