Mohamed Hossam

• Led end-to-end delivery of an 85.02 kWp off-grid solar station with 748 kWh battery storage for Khalda Petroleum, managing design, manufacturing, and commissioning of solar structures and mega battery enclosures. • Achieved 100% on-time delivery and zero safety incidents through rigorous planning, cross-functional coordination, and daily site audits. • Reduced installation downtime by 40% by pre-assembling structural components and using standardized torque procedures, improving system Overall Equipment Effectiveness (OEE) to 96%.

• Designed and prototyped 5 smart industrial products including smart water meters, solar mounting structures, and modular battery enclosures, integrating mechanical design with Siemens S7-1200 PLC controls and sensor networks for real-time diagnostics. • Reduced prototype iteration time by 50% by implementing modular, tool-less assembly systems aligned with Design for Assembly (DFA) and Design for Manufacturability (DFM) principles. • Collaborated with electrical and firmware teams to integrate servo drives, proximity sensors, and pneumatic systems into automated machinery, improving system reliability by 70% and reducing field service calls. • Developed standardized technical documentation and visual troubleshooting guides to support scalable production and reduce Mean Time To Repair (MTTR) by 68%.

• Delivered 200+ precision 2D CAD drawings for mechanical components across solar, automotive, and manufacturing industries, ensuring compliance with ISO 2768 tolerances and client specifications.

• Supervised mechanical installation of 85+ solar panel mounts on rooftop structures, ensuring precision within ±1mm tolerance using laser alignment tools. • Coordinated with civil and electrical teams to resolve 5+ design clashes, preventing over 40 hours of rework and keeping the project on schedule.

• Maintained and repaired 12+ high-speed CNC and PLC-controlled spring-forming machines, achieving 94% uptime over 12 months through a Total Productive Maintenance (TPM) program. • Reduced Mean Time To Repair (MTTR) from 4.1 hours to 1.3 hours by creating visual repair guides, pre-staging critical spare parts, and training 8 operators to perform basic resets — reducing technician call-outs by 60%. • Conducted Root Cause Analysis (RCA) on recurring servo motor failures using vibration and thermal data; identified moisture ingress as root cause and implemented IP67-rated cable glands — resulting in zero motor failures in the last 8 months. • Improved Overall Equipment Effectiveness (OEE) from 71% to 89% by eliminating setup delays and reducing quality defects via real-time torque monitoring.

we were working on a machine which straighten and cuts pc wire , I had designed some of its parts , 2 cutting mechanisms one by eccentric press other by hydraulic cylinder, also I was working on its power and control using plc S7-1200

managing a small work shop with cnc router and laser machine , where I used to take customer requirements and specs to design the required product then look for appropriate way for manufacturing whether by cnc router or laser.also made some maintenance there