Cement Production Manager Looking Globally

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Serial No: 26901

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Skills keywords: cement production expert, commissioning engineer, operation specialist, process engineer, production team leader

List Of Qualifications & Related Skills:

Teamwork
Data analysis
Problem solving

Previous Employment Details:

I have recently (in July 2017) joined Saint-Gobain Gyproc as Production Manager. Before that I was working in Eltakamol Cement –Sudan as Production Manager in charge of all production activities. Before that I was working in Asec Cement – Egypt as Commissioning and Production Head for a new Coal Firing Project. Before that I exited from Albadia Cement Company – Syria, after a 2 year long tenure, as Production Team Leader, and previously worked mainly with Lafarge-Holcim Nigeria. Having mastered in-depth knowledge and experience in plant and process operations, and with developed leadership and management skills, I am a strong candidate for the position I am seeking.

Current location:  Egypt - View on map

Preferred Sector of Employment:  Manufacturing and Operations

Spoken languages: Arabic, english

Location I am interested in working: Anywhere

Profile

Over 12 years’ experience in cement production in international settings. Capable of taking charge from commissioning stage through stabilization of production and day to day production operations. Conversant with all operations of a full-fledged cement plant from crushing to packing with specialized exposure in Kiln & Cement Mill operations. In-depth knowledge of chemistry of cement manufacturing including process, blending, clinkerization (heat and material balance), cooling, grinding, role of additives, etc. to help control process parameters in optimizing productivity and quality. Ability to analyze process data against operational and production pitfalls, and efficient in resolving the inconsistencies Excellent in-plant coordinator and process troubleshooter, driving operations to maximize OEE and throughput. Almost 6 years’ experience with Lafarge – the global leader in cement manufacturing.

Core competencies include ………

 Operations Management

 SOP Development/Review

 Raw Material Coordination

 CCR Operations Coordination

 Process Monitoring/Control

 Maintenance Coordination

 Productivity Enhancement

 Quality/Environment Control

 Operational Troubleshooting

 Commissioning & Start Up

 Training & Development

 Team Building & Leadership

Professional Experience

Jun 2013 – May 2015
Albadia Cement Company – Syria
Production Team Leader

Plant Profile: CBMI Design, 5000 TPD, VRM LOESCHE, Coal fired Kiln – 5m D*80m L, IKN cooler, and VRM LOESCHE Cement mill

In charge of start the plant after takeover from CBMI operation team, building and training local Staff to take all responsibility for smooth operation at site and C.C.R (Central Control Room)

• Develop and establish standard operation procedures for CCR and site.

• Review operational reports, identify root cause of performance gaps, and take corrective/preventive action to improve production performance and plant availability in coordination with appropriate group.

• Ensure the integrity of the process material balance including additives and consumables, while economizing fuel consumption.

• Coordinates production activities with maintenance, process & quality control teams to integrate production interfaces.

• Drive efforts to optimize production and utilization of human resources, machines, and equipment.

• Evaluate and recommend improvements in usage of equipment, material, manpower, performance and quality.

• Manage overtime demands, service requests, and other day to activities for smooth operation of the plant.

Achievements

• Save approximately1000000 USD/year on account of refractory contractors, by developing & engaging own team in brick lining.

• Sourced and implemented a tracking tool to facilitate enhancement of performance and productivity, thus accruing huge saving for the company – trained local staff in its use.

• Modified the additive storage to increase sand pile capacity

May 2010 – Apr 2013
Lafarge Wapco – Nigeria
Kiln Coach

Plant Profile: CBMI design, 5000TPD, VRM LOESCHE, Coal fired Kiln – 5m D*80m L, IKN cooler, and roller press cement mill

Responsible for following commissioning & start up activities, deficiency List, and training of CCRO/site patroller/new shift Leaders

• Evaluate Quality data, Environmental compliances, Established process targets, Process deviation against targets, Workshop reliability and performance factors, CROs individual performance, Control loops and Shift reports.

• Develop & establish SOP for equipment installation, modification, testing, inspection & maintenance according to engineering principles and safety regulations.

• Establish and follow up the operation parameters and take the corrective actions to guarantee steady operation.

• Ensure high levels of equipment performance and optimum operation cost.

• Review and propose improvement of interlocks of production line.

• Coordinate the major maintenance shutdowns with all groups to ensure timely turnaround and maximum future availability.

• Champion end-to-end refractory management – Plan refractory works, Forecast refractory budget, Prepare estimates and specifications, Suggest equipment and tools, Manage overhauls and bricking activities, Establish and design needed modifications, Ensure appropriate coordination with Warehouse, Purchase to facilitate timely availability of refractory materials, Direct maintenance, and ensure training of the staff to achieve a high- level of competency.

Achievements

• Identified a major item uncovered by the contractor under performance guarantee test contract, and persuaded the contractor to include the same within the same cost, thus avoiding future trouble for the company.

• Successfully led the alternate fuel project, and accrued huge saving to the company.

• Instrumental in start up of the plant, and played a stellar role in developing new graduates in plant operations.

Oct 2007 – Apr 2010
Lafarge Unicem – Nigeria
CCR Coach

Plant Profile: FLS design, 6250TPD, VRM Atox 50, Kiln 5m D *80m L, Cross bar cooler SF 4*6, Dual fired (heavy oil and natural gas), 2 cement tube mills

Responsible for commissioning, start up and training of CCR Operators

• Coach and lead CCRO to run the plant with smoothly, while ensuring high performance, sustainability and quality target.

• Review plant performance and put the guide lines for production and process team.

• Establish and follow up the operation parameters and take the corrective actions that guarantee steady operation and ensure high equipment performance with optimum operation cost; review and propose improvement of interlocks of production line.

• Review and develop kiln performance report, Tracking tools and process report.

• Evaluate Quality data, Environmental compliances, Established process targets, Process deviation against targets, Workshop reliability and performance factors, CROs individual performance, Control loops and Shift reports.

Achievements

• Modified the oil fuel unloading system after its failure.

• Put the new equipment start/stop sequence and interlocks.

• Increase air shock at certain places to prevent material blockage, due to repeated blockage at preheater cyclones.

Apr 2004 – Sep 2007
ASEC Cement – Egypt
CCR Operator ((Crushers, Vertical Raw mill, Kiln, Cement mills, packing plant)

Plant Profile: FLS design, 5000TPD, VRM Atox 42.5, Kiln 4.5mD*74mL, Coolax Grate Cooler, Dual fired (heavy oil and natural gas), 2 cement tube mills.

Responsibilities

• In charge of DCS operation for all plant areas

• Follow up the operation parameters of the equipment to ensure smooth equipment operation.

• Identify and analyze data, indicators and trends of the production process, provided by digital control system in order to implement preventive and/ or corrective action to improve the equipment performance.

• Identify and analyze the characteristics of the product (clinker and cement) based on quality control results and on analyses of quality indicators measured by the operational system.

• Implement timely corrective actions to comply with the established quality parameters.

• Follow up the equipment operation data (temperature, pressure, feed, flow) and ensure the stoppage and start-up of equipment comply with the safety standards.

• Control & optimize heat consumption, power consumption, dust emission, NOX, CO2 emission, etc.

Qualifications & Training

• Bachelor of Science, Zagazig University – Egypt, 2002

Trainings & Courses

• IELTS International English Language Training System 2015

• Project Management Professional- PMP (AUS, American university of science 2012)

• Coal firing operation and safety (Lafarge Kenya2011)

• Quarry Management and Crusher Operation (Lafarge Nigeria 2008)

• Leadership and Team work Management (Egypt 2007)

• ACMC, ASEC Cement Manufacturing Course 2006

• Raw Mix Design (ASEC Egypt 2005)

Other Particulars

• Full Name: Usama Ibrahim Abdelglil Awad Mohamed

• Date of Birth: September 27, 1981

• Languages Known: Arabic and English

• Computer Proficiency: MS Office, Primavera, Sap, Internet

• Nationality: Egyptian

• Marital Status: Married, 3 dependents

• Passport No: A06865708, valid till 07/05/2019

• Alternate Contacts: (M) +201002823349; (E-Mail) usamakz539@gmail.com