Mohamed Abd El Fatah ,MBA,CM

Experience

• 

  Cimpor Group

  Sept 2003 - Feb 2011

  Main job Activities & responsibilities:• Ensure to operate according standard operation procedure• Supervise production employees to ensure kiln and mills are operated in optimum Conditions.• Ensure kiln and mill operation are in environmental compliance• Assure that a consistent, quality product is producing through Interaction with the quality control department.• Take corrective action as necessary and report and recommend solutions for production problem areas.• Assure the regular inspection and evaluation of all operating equipment to help maintain production requirements.• Measuring Fans efficiencies and inspect fans overlap and clearance in shutdowns and when required.• Detecting False Air locations, which reduce the overhaul expenses of steel sheath, man power, cost and reducing the shutdowns times.• Work to keep costs related to work in line with the plant budget and be alert for ways to reduce costs of operations, maintenance and repairs• Conducted Material Balance, Gas Balance, Fuel Balance and Pyro-Process study for optimization.• Cement mills Auduiting and reporting Major Achievement• Cement mills optimization by increase cement mill performance by 5 % and cement mill power consumption by 2 %• Decrease By-Pass Ratios about 3% by controlling the Alkali sulfate ratios in the phase of raw mix design• Decrease kiln heat consumption by 2 %• Increase kilns MTBF to be 300 hours• Optimize the kin preheater temperature profile by modify preheater precalciner to be multi stage burner Show less Start-up & commissioning operator Ameryah Cimpor Cement Co. Line 3.• Mixture Circular storage (Chevcon & cone shell methods) and High grade longitudinal storage upgrade (chevron method) for three lines.• Vertical 2.7/5.4 mill with output 420 t/h.• Raw meal CF silo 17000 m3.• Short kiln with “5” stage preheater, CC calciner, by pass system Hydraulic grate cooler 4600 T/H.• Cement mill 5.4m with performance output 220 t/h.• Two Cement silo each one 10000 tons.• 3 packing machine 120t/h. Activities:Operate, monitor and manage operations of the kiln,mills and clinker coolerareas according to required operating standards for ensuring continuous operations and delivery of high quality products to end-users. Commissioning & start up of line 3 cement production • ( Polysius technology & ABB industrial IT application )• Responsible of processing the plant through DCS system• Operation of rotary kiln furnace• Cooling tower• Heavy oil boiler• Instrument air compressor • (Vertical mill & ball mills & rotary kiln & grate cooler )Supervise of raw material storage Show less

  • Process Engineer

    Apr 2009 - Feb 2011

  • Line Operator

    Sept 2003 - Apr 2009
• 

  InterCement

  Mar 2011 - Mar 2019

  General Production department manager at Ameryah Cement (intercement)Main job Activities & responsibilities:• Follow and support employees to follow the company safety roles and slogan ‘‘safety is value’’• Issuing the required safety procedures for all critical activities in all production process.• Met KPIs, slashed operational costs, and increased efficiency of systems through analysis and continuous improvement by implement PDCA system • Arrange all activities with all departments.• Establish and control the plant production budget and KPI’s.• Created annual equipment maintenance schedules by collaborating with maintenance department• Plan and control all production needs refractories, ball charge and material.• Building Team motivation training programs.• Control Variable and fixed cost and quarter evaluation to reach the company EBITDA.• Contracts and contractors control (cleaning, operation, material transportation).• Flash report for end of each month (invoices and deviation control).• Cost reduction, power saving and equipment optimization. • Responsible for plant performance, reliability, productivity.• Responsible for 5 S programs.• Planning and control with supply chain team all requirement from fuel (, coal, petcock, heavy oil, AF). Control the shredded tires facility. • Contribute with purchase team the process of contracts issuing and renewing. Major Achievement • Be part of team achive 455 working days with zero Lost Time Incident ( ZRO LTI )• Earned 2017 Excellence Performance Award from the business unit CEO and VP Africa and promoted in recognition of outstanding performance• Led products portfolio ranging from two to six products in the market and optimising business revenue ~$2.5M EBITDA• Optimize kiln process to utilize solid fuel as main fuel keeping the same kilns performance and reliability.• Saved costs approximately 4.5 USD/ton through successful diversification of thermal energy matrix. Show less Main job Activities & responsibilities:• Coordinate the coal mill project (start up and commission )• Management kiln operation.• Control kiln Reliability and performance.• Decrease Heat consumption & power consumption.• Plan yearly kiln shut down as preventive maintenance.• Supervising refractory works during kiln shut down.• Control Refractory consumption.• Management raw mills operation.• Raw mill performance and reliability.• Ball charge wears rate and consumption.• Analyze causes of trouble shooting occurred during the shifts (RCA report).• Issuing daily and monthly reports to control plant operation.• Coordinator reliability committee to implement all plans for maintenance and prevent problem repetition.• Management cleaning and flow process for all area and by pass system.• Member of contractors' management subcommittee. Major Achievement• Achieve 35 % AF TSR in kiln No 3• Coal mills commissioning and start up• Alternative fuel system ( VICOPLAN system ) commissioning and start up• Optimize kiln process to utilize alternative fuel keeping the maintained kilns performance and reliability.• Lead the team earned intercement PDCA world cup competition between 21 plants for continues performance improvement• Sustain kiln 3 to be the top of intercement group in performance and reliability three consecutive years Show less

  • Production Manager

    Jul 2017 - Mar 2019

  • Clinker Manager

    Mar 2011 - Jun 2017
• 

  Arab Swiss Engineering Company "ASEC"

  Apr 2019 - Dec 2021

  Plant Manager

  Plant manager at ASECMain job Activities & responsibilities:• Follow and support employees to follow the company safety roles and slogan ‘‘safety is value’’• Issuing the required safety procedures for all critical activities in all production process.• Met KPIs, slashed operational ,maintenance costs and increased efficiency of systems through analysis and continuous improvement by implement PDCA system • Manage the operation and maintenance staff to ensure timely production and distribution of products within quality standards,and optimum production cost.• Responsible for the development and execution of annual operation plan .• Review cost reports to locate excessive expenses and takes necessary corrective actions .• Prepare short and longe range development plan .•. Establish goals that reflect continuous improvement in plant operations.•. Train and develop supervisors to provide management depth,provide motivation and career enhancement for all employee.•. Establish and control the plant budget and KPIs.•. Create annual equipment maintenance schedule by collaborating with maintenance department.•. Building Team motivation training programs.• Control Variable and fixed cost and quarter evaluation to reach the company EBITDA.• Cost reduction and power saving and equipment optimization.• Responsible for plant performance,reliability,productivity.Flash report for end of each month (invoices and deviation control).• Cost reduction, power saving and equipment optimization. • Responsible for plant performance, reliability, productivity.Major Achievement • contribute to decrease clinker variable cost by 15%.•. Decrease specific power consumption from 155kwh/ ton of cement to 142 . •. Improve kiln productivity achieve 1500TBD .•. Improve kiln reliability achieve 98 %.•. Contribute to decrease fixed cost .•. Contribute to decrease warehouse value . Show less

• 

  City Cement Company

  Nov 2021 - now

  Plant Manager responsible for■ Two Cement Production Line• Two kiln production line 5500 TPD clinker x 2.• 3 Cement Mills with Roller press including packing Area.• Plant Quarry operation management ■ Power Plant generation• Power plant (10 Diesel Engine) 81.3 MW.• Waste Heat Recovery (WHR), steam turbine 14.2 MW.■ All plant utilities• Water stations from Bore wells.• Mobile heavy equipment.• Water Treatment.• Alternative fuel facility, RDF + TDF.My Job Duties:-• Follow and support employees to follow the company safety roles and slogan ‘‘safety is value’’• Issuing the required safety procedures for all critical activities in all production process.• Link business strategy with plant operations.• Responsible for industrial operation optimization and energy management • Met KPIs, slashed operational costs, maintenance cost and increased efficiency of systems through analysis and continuous improvement.• Manage the operation and maintenance staff to ensure timely production and distribution of product within quality standards, and optimum production costs.• Responsible for the development and execution of annual operation plan.• Review cost reports to locate excessive expenses and takes necessary corrective actions.• Prepare short and long range development plan.• Establish goals that reflect continuous improvement in plant operations.• Train and develop supervisors to provide management depth, provide motivation and career enhancement for all employee.• Establish and control the plant budget and KPI’s.• Created annual equipment maintenance schedules by collaborating with maintenance department• Building Team motivation training programs.• Control Variable and fixed cost and quarter evaluation to reach the company EBITDA.• Cost reduction, power saving and equipment optimization. • Responsible for plant performance, reliability, productivity. Show less Industrial operations manager responsible for■ Two Cement Production Line• Two kiln production line 5500 TPD clinker x 2.• 3 Cement Mills with Roller press including packing Area.• Plant Quarry operation management ■ Power Plant generation• Power plant (10 Diesel Engine) 81.3 MW.• Waste Heat Recovery (WHR), steam turbine 14.2 MW.■ All plant utilities• Water stations from Bore wells.• Mobile heavy equipment.• Water Treatment.• Alternative fuel facility, RDF + TDF.My Job Duties:-• Follow and support employees to follow the company safety roles and slogan ‘‘safety is value’’• Issuing the required safety procedures for all critical activities in all production process.• Link business strategy with plant operations.• Responsible for industrial operation optimization and energy management • Met KPIs, slashed operational costs, maintenance cost and increased efficiency of systems through analysis and continuous improvement.• Manage the operation and maintenance staff to ensure timely production and distribution of product within quality standards, and optimum production costs.• Responsible for the development and execution of annual operation plan.• Review cost reports to locate excessive expenses and takes necessary corrective actions.• Prepare short and long range development plan.• Establish goals that reflect continuous improvement in plant operations.• Train and develop supervisors to provide management depth, provide motivation and career enhancement for all employee.• Establish and control the plant budget and KPI’s.• Created annual equipment maintenance schedules by collaborating with maintenance department• Building Team motivation training programs.• Control Variable and fixed cost and quarter evaluation to reach the company EBITDA.• Cost reduction, power saving and equipment optimization. • Responsible for plant performance, reliability, productivity. Show less Industrial operations manager responsible for■ Two Cement Production Line• Two kiln production line 5500 TPD clinker x 2.• 3 Cement Mills with Roller press including packing Area.• Plant Quarry operation management ■ Power Plant generation• Power plant (10 Diesel Engine) 81.3 MW.• Waste Heat Recovery (WHR), steam turbine 14.2 MW.■ All plant utilities• Water stations from Bore wells.• Mobile heavy equipment.• Water Treatment.• Alternative fuel facility, RDF + TDF.My Job Duties:-• Follow and support employees to follow the company safety roles and slogan ‘‘safety is value’’• Issuing the required safety procedures for all critical activities in all production process.• Link business strategy with plant operations.• Responsible for industrial operation optimization and energy management • Met KPIs, slashed operational costs, maintenance cost and increased efficiency of systems through analysis and continuous improvement.• Manage the operation and maintenance staff to ensure timely production and distribution of product within quality standards, and optimum production costs.• Responsible for the development and execution of annual operation plan.• Review cost reports to locate excessive expenses and takes necessary corrective actions.• Prepare short and long range development plan.• Establish goals that reflect continuous improvement in plant operations.• Train and develop supervisors to provide management depth, provide motivation and career enhancement for all employee.• Establish and control the plant budget and KPI’s.• Created annual equipment maintenance schedules by collaborating with maintenance department• Building Team motivation training programs.• Control Variable and fixed cost and quarter evaluation to reach the company EBITDA.• Cost reduction, power saving and equipment optimization. • Responsible for plant performance, reliability, productivity. Show less

  • Industrial Director

    Jan 2024 - now

  • Plant Manager

    Apr 2022 - May 2024

  • Industrial operations manager

    Nov 2021 - Apr 2022

  • Industrial operations manager, MBA , CM

    Nov 2021 - Dec 2021