Basic Info

Mostafa Rafik

10 years

Cairo, Egypt

Bachelor's Degree

Manager

Work Experience

Factory Maintenance Manager at HUNGRY BUNNY FACTORY FOR MEAT PROCESSING, Dammam, Saudi Arabia

Experience Details

Factory Maintenance Manager

Operations/Management, Engineering - Mechanical/Electrical

Manager

 Manage and monitor equipment installations & commissioning for new factory.
 Handle all warranty issues.
 Maintain inventory of all spare mechanical and electrical parts, storing, classifying, coding, and monitoring the use of local and imported equipment.
 Design and implement systems and plans for streamlining factory maintenance and repairs. Create Factory Maintenance Plan, scheduling time-based and condition-based maintenance and building execution maintenance calendar. Run Repair Reporting System, identifying type of maintenance, time, and parts used.
 Administer department budget, preparing yearly capital expenses and tracking all monthly maintenance costs. Recommend purchase of new equipment and machinery.
 Lead team of multi-disciplinary maintenance engineers and technicians, coordinated work flow by prioritizing and delegating tasks, providing motivation and direction to create a positive work environment and ensure accurate, on-time maintenance and repair.
 Set KPI’s and benchmarking which support business aims and operating strategy %Uptime, TMC as % of RAV, MTBF, % Planned ,% Emergency work , Workweeks backlog, Stock turn ratio and Planned Work Schedule compliance, % over time and maintenance labor cost as % of TMC.

Achievements
 Modify forming drum equipped in forming machine to produce a new innovative product to meet Top management strategically targets in reducing waste , increasing capacity , increasing quality and increasing man power utilization with minimum budget. Modification Cost 15K which saved 60K SR to buy new forming Drum with price 75K SR.
 Redesigned bone saw to automate Block Cutting to increase capacity, safety and reduce man power.
 Design and execute flour dust collector which provide good environment inside processing area clear of dust and airborne fine flour with percentage of 90%, Reduce producing line and A/C evaporator failure rates which occurs due to dust accumulation in bearings, electrical panels and evaporative blockages.
 2015 TMC 2.5% RAV.
 Stock Turn Ratio = 0.7.
 Start Applying Predictive test and inspection techniques by using IRT (Infrared Thermograph) for Electrical components condition monitoring and inspection beside normal visual inspection and monitoring.
 Good tracking for warranty issues and deep understanding for equipment functions and monitoring systems set the company aside to pay for new pump 15K SR even after official warranty expiration and bind the contractor to change pump with same standards for free.


Company Details

HUNGRY BUNNY FACTORY FOR MEAT PROCESSING, Dammam, Saudi Arabia

Dammam, Saudi Arabia

501-1000 employees

Food and Beverage Production, FMCG

www.Hungrybunny.com.sa

Sep 2013 to Nov 2016 (3 years 2 months)
Mechanical Maintenance Manager at UFI & UCI FOR PASTA, TOMATO PASTE & CONCENTERATIONS

Experience Details

Mechanical Maintenance Manager

Engineering - Mechanical/Electrical, Operations/Management

Manager

 Managed efficient operation, troubleshooting causes of breakdowns and repairing equipment to mitigate failure rates and consequences.
 Installed new jars filling line for tomato paste. Changed path of main steam pipeline and installed needed valves, gauges, strainers, and expansion loops. Installed new jar line and juice filling line and equipped labeling and shrink machines with conveyors.
 Maintained inventory for spare parts, ensuring quality of new parts before adding to stock and ordering required parts, whether local or imported.
 Supervised crew of technicians, evaluating performance and prioritizing and delegating tasks based on daily meetings with chairman. Scheduled periodic maintenance.
 Used SAP applications to manage production operations and maintenance scheduling. Measured KPIs: % Completed work orders, Uptime%, MTBF, % Planned, % Emergency work, Workweeks backlog.

Achievements
 Decreased waste water by 90% and increased water ring vacuum pump efficiency and reliability by installing cooling tower. Investment payback within six months from net cash outflow generated through reducing pumps maintenance cost, production line unplanned outages and water consumptions.
 Reduced Seaming M/C head breakdown time from four hours to a maximum of one hour by designing a new method for changing broken ejector springs. Scheduled periodic spring changes during planned stoppages, to decrease failure consequences and rate of occurrence of failure.
 Increase Pasta and Concentration factories availability and decrease unplanned outages by execute failures analysis , analyze historical rate of occurrence of failures , risk assessment and tasks prioritization by coordinating with production department for planned stoppage, Continuous improvements in maintenance tasks and applied maintenance strategies , Execute Overhauling to oldest pasta Line (Capacity 1 ton/hr) up on standard parts and materials with precise tolerances to avoid infant mortality zone after overhauling .


Company Details

UFI & UCI FOR PASTA, TOMATO PASTE & CONCENTERATIONS

Badr Industrial city, Egypt

501-1000 employees

FMCG, Food and Beverage Production

www.ufieg.com

Nov 2011 to Sep 2013 (1 year 10 months)
Mechanical Maintenance Head at Al-Nour For Dairy Industries (Lactalis, President proceed Cheese).

Experience Details

Mechanical Maintenance Head

Engineering - Mechanical/Electrical, Manufacturing/Production

Experienced (Non-Manager)

N/A


Company Details

Al-Nour For Dairy Industries (Lactalis, President proceed Cheese). (multinational)

Obour city, Egypt

More than 1000 employees

FMCG, Food and Beverage Production, Dairy

N/A

Jul 2006 to Nov 2011 (5 years 4 months)

Achievements


 Modify forming drum equipped in forming machine to produce a new innovative product to meet Top management strategically targets in reducing waste , increasing capacity , increasing quality and increasing man power utilization with minimum budget. Modification Cost 15K which saved 60K SR to buy new forming Drum with price 75K SR.
 Redesigned bone saw to automate Block Cutting to increase capacity, safety and reduce man power.
 Design and execute flour dust collector
which provide good environment inside processing area clear of dust and airborne fine flour with percentage of 90%,
 2015 TMC 2.5% RAV
 Stock Turn Ratio = 0.7
 Start Applying Predictive test and inspection techniques by using IRT (Infrared Thermograph)
 Good tracking for warranty issues and deep understanding for equipment functions and monitoring systems set the company aside to pay for new pump 15K SR even after official warranty expiration and bind the contractor to change pump with same standards for free.


 Decreased waste water by 90% and increased water ring vacuum pump efficiency and reliability by installing cooling tower. Investment payback within six months through reducing pumps maintenance cost, production line unplanned outages and water consumption.
 Reduced Seaming M/C head breakdown time from four hours/occasion to a maximum of one hour by designing a new method for changing broken ejector springs. Scheduled periodic spring changes during planned stoppages, to decrease failure consequences and rate of occurrence of failure.
 Increase Pasta and Concentration factories availability and decrease unplanned outages implementing precise maintenance procedures with assuring sustainability.



 Modify driving system of volumetric filling machine to increase productivity and machine speed.
Redesigned cheese supply and CIP lines for new jar filling and production lines, installing appropriate pneumatic actuators to achieve targets. Modified pump by integrating analog and digital level switches, saving ‎£150K LE and reducing downtime.
Using reverse engineering concepts saved 85% of parts cost .
Increase UHT, Grinders and Mixers availability and decrease unplanned stoppage through precise implementing to maintenance plane with minimum backlog tasks.
Modify Cookers Sealing Shaft seal and base which reduce motor rewinding cost 80% from 4 times / year to 0-1 time / year.
Nominated to be maintenance division representative in small team to travel Germany and take intensive training on installation, commissioning, operation , maintenance and repair for new Slices Proceed Cheese production machine


Education

BSc in Mechanical Engineering

Education Details

BSc

Mechanical Engineering

Helwan University, Egypt

C / Good / 65 - 75%

N/A

N/A

Helwan University
1998 - 2004

Training and Courses

Training/Course Details

Reliability centered Maintenance

Nov 2015

lifetime time reliability solution

Foundation Reliability Knowledge and Basics Recognising Operating Equipment Risk Identifying the Effects of Failure Proactive Maintenance Strategy Reliability Centered Maintenance Method Integration and Implementation of RCM Perform an RCM Analysis for Maintenance Strategy Making Changes to an Existing Maintenance System Techniques for Equipment Reliability Growth Complete a RCM Analysis of Operating Equipment

Training/Course Details

RCFA (Root Cause Failure Analysis

Jun 2016

lifetime time reliability solution

Root Cause Failure Analysis Process Root Cause Failure Analysis Methodology Failure Investigation Steps and Evidence Collection Six Key Failure Investigation and Analysis Tools – Pareto Chart, FTA, Is-Is Not Table, Fishbone, FMEA, 5-Why Business Process Risk and Human Error RCFA Teams and Investigation Facilitation Basics Reliability Improvement Process and its Management Creative Disassembly of Machinery Component Failure Accuracy Controlled Work Quality Assurance Procedures Perform a Case Study Root Cause Analysis and RCFA Report

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Last update 3 days ago.

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Profile Skills and Keywords

Al-Nour For Dairy Industries (Lactalis, President Proceed Cheese).AnalyticalArabicCworks CMMSDairyEnglishFMCGFactory Maintenance ManagerFood And Beverage ProductionFrenchHard WorkerKPI'SLeaderMS.officeManagementManufacturingMechanical EngineeringMechanical Maintenance HeadMechanical Maintenance ManagerOEEOperationsPlaningPlannerProductionRCFA (Root Cause Failure AnalysisReliability Centered MaintenanceSAP CMMSSchedulingSolid Edge ST4Supportive

Self-assesed Skills

Languages

Arabic

Arabic

: Fluent

: Fluent

: Fluent

: Fluent

English

English

: Advanced

: Advanced

: Advanced

: Advanced

French

French

: Beginner

: Beginner

: Beginner

: Beginner

Tools and Technologies

MS.office

MS.office

: Advanced

: High

:

More than 7 years

SAP CMMS

SAP CMMS

: Advanced

: High

:

1-3 years

Solid Edge ST4

Solid Edge ST4

: Advanced

: High

:

5-7 years

Cworks CMMS

Cworks CMMS

: Intermediate

: High

:

Less than 1 year

Fields of Expertise

Planing

Planing

: Advanced

: High

:

More than 7 years

scheduling

scheduling

: Advanced

: High

:

More than 7 years

KPI'S

KPI'S

: Advanced

: High

:

3-5 years

OEE

OEE

: Intermediate

: High

:

3-5 years

Key Skills

Analytical, Leader, Planner, Hard worker, Supportive

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