Ali Sayegh

• Oversee planning activities for mechanical, electrical, and production maintenance across the entire plant. • Develop daily maintenance plans and work orders, including manpower allocation and required spare parts to complete tasks efficiently. • Responsible for preparing/monitoring the annual budget for the maintenance department, including detailed forecasting of spare parts, tools, and outsourced maintenance services. • Prepare Bills of Materials (BOM) for all plant equipment and machinery. • Create preventive maintenance schedules in SAP and monitor the work order flow to ensure timely execution. • Coordinate with maintenance teams, contractors, and external vendors to optimize work execution. • Plan and schedule shutdown activities, ensuring optimal allocation of personnel and resources to meet deadlines. • Generate Purchase Requests (PR) for spare parts and prepare Scope of Work (SOW) documents for projects and services. • Lead weekly maintenance and downtime review meetings to improve operational performance. • Manage spare parts inventory by implementing min/max stock levels and re-order points. • Develop and maintain maintenance department procedures in line with the Integrated Management System (IMS) requirements. • Prepare detailed maintenance instructions, including checklists, calibration schedules, and plans based on OEM manuals. • Maintain and update IMS documentation for the maintenance, including procedures, work instructions, and related records. • Responsible for implementing, maintaining, and ensuring compliance with ISO 50001 Energy Management System requirements within the maintenance scope, including energy performance monitoring, documentation control, and audit preparation. • Lead internal audits to verify IMS compliance, identify improvement areas, and ensure readiness for external audits.

During the co-op training period that I partook with Yanbu Cement Company, I covered various aspects in the plant regarding the mechanical execution tasks and the general process flow of manufacturing cement. Which starts with the strategic location of the plant next to the quarry where limestone is crushed and conveyed over to the storage gantry where it is homogenized and conveyed once again into the raw material silos to be prepared in set quantities for grinding and mixing in the raw mills. The next phase is known as the "pyro-process" where the material is further dried up to avoid moisture and calcined in the preheater cyclone stages. The material only takes approximately thirty seconds to pass through all the preheater cyclones where it leaves into the kiln entry being 96% calcinated. The material then enters the rotary kiln which is lined from the inside with refractories that act as heat insulators and serve the purpose of protecting the kiln shell from the high temperatures inside the kiln that could rage up to 1350C. The material passes through various chemical stages and sintering where it ends up forming what is known as clinker. The clinker then drops into the cooler where due to the high levels of heat exchange is quenched and cooled to approximately 100C. This cooled clinker is then conveyed once more into the clinker silos where it is stored and conveyed in quantities to the cement mill to serve its grinding along with the other additives based on the type of cement that is to be manufactured. However, the subjects that were covered in-depth are those of material handling here at the plant such as the various belt conveyors, bucket elevators, and air slides. Worth mentioning was the tasks and procedures that I was assigned during the shutdown which helped drastically boost my knowledge regarding the whole process of manufacturing cement.