Kamran Ali

Experience

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  Vehicle / Equipment Rebuild Production Facilities, Pakistan

  Oct 1994 - Oct 2017

  Manager Maintenance, Engineering Production & Quality Management

  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 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 Engines rebuild shop revamping for Euro engines resulted in enhanced rebuild engine production by more than 200%.o Quality Control /Quality Assurance stages layout improvement and introduced Quality Cell at Vehicle Rebuild Production Facility. Show less

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  Industrial Production Facility, Pakistan

  Aug 2006 - Sept 2009

  Senior Inspection Officer

  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.

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  EME Centre

  Aug 2014 - Jul 2016

  Technical Training Officer

  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.

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  Fauji Fertilizer Bin Qasim limited (FFBL)

  Feb 2018 - Dec 2020

  Unit Manager Workshop

  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 modification project of Suspension Air Bellows base plate in two models of Phosphoric 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 Self-sustenance projects to revitalize critical plant mobile equipment & machinery resulted in a 35% reduction of rental equipment during the plant's annual turn-around.o Trained Sub Engineer and Supervisors for QC inspections and implemented QA in the maintenance process. Show less

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  DP World

  Dec 2020 - Aug 2024

  Manager Mechanical ITV

  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 Terberg ITVs with OEM to eliminate critical defects. o Diagnosed engine oil consumption through RCA and eliminated it in all Cummins engines.o Enhanced safety and workflow through Lean methodologies/Kaizen-driven improvements and budget optimization.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 in the first year.o Proposed EV shuttles for terminal & Pilot project comprising 4 EV shuttles for 12 passengers along with 3 fast charging stations at planned locations with maintenance backup was approved by DP World's head office in UAE.o Successful Pilot project to reduce operator fatigue through virtual monitoring alerts and 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 Developed 4- & 8- year PM plans by analysis of CMMS data to predict equipment failures leading to a 50% reduction in downtime.o Successfully revitalized legacy mobile equipment thereby contract to hire a 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. Show less