Maintenance Manager/ Mechanical Engineer

Ahmed Mahfouz CMRP®

Maintenance & Reliability Engineer CMRP® TPM • RCM • RCFA • FMEA

Dammam, Saudi Arabia, Mobile: +966-***-***-***

Email: ****************@*****.***, LinkedIn: (3) Ahmed Mahfouz, CMRP® LinkedIn PROFESSIONAL SUMMARY

Certified Maintenance & Reliability Professional (CMRP) and Mechanical Engineer with 12+ years of experience in maintenance management, reliability engineering, and heavy industrial operations. Proven track record applying Total Productive Maintenance (TPM), Reliability-Centered Maintenance (RCM), Root Cause Failure Analysis (RCFA), and Failure Mode and Effects Analysis

(FMEA) to improve asset reliability and reduce unplanned downtime. Skilled in preventive & predictive maintenance (PM/PdM), condition-based maintenance (CBM), CMMS/EAM systems, and maintenance cost optimization. Strong leadership background managing multidisciplinary maintenance teams, improving MTBF, MTTR, and OEE, and aligning maintenance strategies with business objectives. Seeking a senior role in Maintenance, Reliability, or Asset Management. CORE COMPETENCIES

• Maintenance & Reliability Engineering

• Total Productive Maintenance (TPM)

• Reliability-Centered Maintenance (RCM)

• Root Cause Failure Analysis (RCFA / RCA), 5-Why, Fishbone/Ishikawa

• Failure Mode and Effects Analysis (FMEA)

• Preventive & Predictive Maintenance (PM / PdM)

• Condition-Based Maintenance (CBM) & Condition Monitoring

• Vibration Analysis, Oil Analysis & Thermography

• Reliability KPIs: MTBF, MTTR, Availability, OEE

• Asset Management & Lifecycle Costing

• CMMS / EAM Systems (ERP 365, Dynamics AX)

• Maintenance Planning, Scheduling & Turnaround/Shutdown Management

• Budgeting, Cost Control & Spare Parts Management

• Lean Maintenance, 5S & Kaizen & Lean Manufacturing

• Project Management & Commissioning

• Heavy Equipment & Rotating Machinery

• Safety, Risk Management & HSE Compliance

• Leadership & Team Development & Continuous Improvement PROFESSIONAL EXPERIENCE

Maintenance Supervisor

Saudi Ready-Mix Concrete Company (SRMCC) Grinding Plant – Dammam, Saudi Arabia Oct 2018 – Present

• Lead preventive, predictive, and corrective maintenance activities for grinding and mortar plants, covering ball mills, gearboxes, compressors, conveyors, bucket elevators (chain & belt), hydraulic systems, and cement packing machines.

• Implemented Condition-Based Maintenance (CBM) and Predictive Maintenance (PdM) programs, reducing maintenance cost per ton by 10–15%.

• Championed Total Productive Maintenance (TPM) initiatives across the plant, engaging cross- functional operations and maintenance teams to reduce unplanned downtime and improve Overall Equipment Effectiveness (OEE).

• Conduct Root Cause Failure Analysis (RCFA) for chronic failures using 5-Why and Fishbone/Ishikawa techniques and deploy long-term corrective actions.

• Apply Failure Mode and Effects Analysis (FMEA) on critical rotating and static equipment to proactively identify failure modes and reduce breakdown risk.

• Improved equipment reliability by increasing MTBF by ~20% and reducing MTTR by ~30% through structured RCFA and reliability-centered maintenance optimization.

• Manage annual maintenance budgets and monitor reliability KPIs to ensure cost efficiency and operational excellence.

• Supervise spare parts inventory, optimizing stock levels to ensure asset availability while minimizing capital lockup.

• Utilize CMMS/EAM systems (ERP 365, Dynamics AX) for work order management, planning, history tracking, and reporting.

• Lead installation, alignment, commissioning, and overhauls of major equipment including Flender gearboxes and rotor impact mills.

• Ensure compliance with safety standards, HSE regulations, and company maintenance policies.

Site Mechanical Engineer

Building & Construction for Contracting Est. (BAC) – Saudi Arabia Jan 2015 – Oct 2018

• Supervised maintenance and repair of heavy machinery, trucks, and industrial equipment for Saudi Aramco projects.

• Developed and executed preventive maintenance plans, improving equipment uptime and reducing corrective maintenance costs.

• Managed daily maintenance reports, schedules, and workforce allocation.

• Coordinated procurement and allocation of spare parts for dismantled and overhauled equipment.

• Inspected delivered equipment to verify technical compliance and operational readiness.

Mechanical Engineer

Hanzada for Importing & Exporting – Cairo, Egypt

Mar 2014 – Jan 2015

• Inspected, diagnosed, and reconditioned commercial vehicles (IVECO, Mercedes trucks).

• Performed fault diagnosis using advanced diagnostic tools.

• Maintained workshop efficiency, safety, and quality standards. Site Mechanical Engineer

Wadi Kom Ombo for Land Reclamation & Contracting – Toshka, Egypt Jan 2013 – Mar 2014

• Maintained and repaired heavy equipment including dozers, excavators, and concrete mixers.

• Calculated spare parts requirements and controlled maintenance costs.

• Executed preventive servicing, timing belt replacement, and mechanical overhauls. KEY PROJECTS & TECHNICAL ACHIEVEMENTS

• BHS Crusher & Haver Boecker Screen Installation (2019): Led installation and commissioning achieving 40 TPH throughput with reduced downtime.

• Mill Shell & Flender Gearbox Replacement (2021): Delivered project on schedule with improved mill reliability and efficiency.

• Gearbox Upgrade (SEW to Flender – 2023): Enhanced reliability of the first production line while minimizing shutdown duration.

• Bucket Elevator Conversion (Chain to Thermal Belt): Reduced downtime to 4 days and saved > SAR 140,000 in spare parts.

• In-House Ball Sorting Machine: Designed and fabricated using scrap materials, eliminating new capital cost.

• Vertical Screw Conveyor Wear Reduction: Implemented compressed-air solution extending shaft life.

• Mill Bearing Oil Cooler Integration: Prevented overheating and unplanned shutdowns during summer operations.

• Dryer Tire Crack Repair: Executed precision welding in-house, saving > SAR 100,000. EDUCATION

Bachelor of Mechanical Engineering

El Minia University – Egypt

Graduated: 2011

CERTIFICATIONS & PROFESSIONAL DEVELOPMENT

• Certified Maintenance & Reliability Professional (CMRP) – SMRP

• Six Sigma Principles – Coursera

• Engineering Project Management (Scope, Time & Cost) – Coursera

• Coaching Practices – Coursera

• Principles of Management – Coursera

• Electric Industry Operations & Markets – Coursera

• Leadership & Emotional Intelligence – Coursera

• Safety Training (30 Hours): H2S, Risk Assessment, Fall Protection, Fire Safety TECHNICAL & SOFT SKILLS

• Reliability Engineering & Asset Management

• Maintenance Strategy Development

• Planning, Scheduling & KPI Monitoring

• Budget Control & Cost Reduction

• Risk Assessment & Safety Compliance

• Team Leadership & Coaching

• Data Analysis & Reporting

LANGUAGES

• Arabic: Native

• English: Fluent

PERSONAL INFORMATION

• Nationality: Egyptian

• Marital Status: Married, one child

• Date of Birth: 04 May 1989

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