ENGINEERING AND MAINTENANCE HEAD

Job Description : ENGINEERING AND MAINTENANCE HEAD EGYPT The incumbent will be responsible for leading and managing the entire Engineering and Maintenance function in the upcoming Fertilizer plant manufacturing Phosphoric Acid, Sulphuric Acid and Phosphate Fertilizers in Egypt Responsibilities : Engineering Standards, Processes and EHS systems To establish engineering standards, SOPs, design specifications, reliability guidelines and maintenance philosophies for all units. Put a system in place for compliance with statutory and regulatory norms , pressure vessels, static and rotary equipment, lifting equipment, building and structures, electrical safety, hazardous area classification, environmental regulations etc. Put a rigorous planning process in place for planning of spare parts to ensure 100% availability of identified spare parts. Apply methods such as ABC analysis and reliability-based stocking. Establish best practices such as TPM, RCM, FMEA and RBI and implement across the plants. To ensure technical audits and closure of observations (HSE, PSM, ISO, OEM, insurance). Ensure strict adherence to safe engineering practices, PSSR, MOC, PTW, LOTO, and overall Process Safety Management. To review and approve the Planned, Preventive and Predictive maintenance schedules for all equipment (Mechanical, Electrical & Instrumentation) according to vendors recommendations and industry best practices. Put system in place to ensure Zero Accidents in workplace including internal safety audits system. Maintenance Planning & Asset Reliability, Performance Monitoring and Improvements : Establish targets continually improve high level OEE and achieve global benchmarks in reliability KPIs. Put a rigorous process in place for monthly review of the maintenance KPI performance , monitor OEE, MTBF, and to identify areas of improvements To monitor effectiveness of Preventive and Predictive maintenance programs and drive improvements. Develop and implement Asset Integrity Management System (AIMS) including inspection intervals, NDT planning, corrosion monitoring, vibration analysis, thermography and thickness measurement. Monitor and eliminate losses using TPM methodology. Drive reduction in unplanned downtime and Mean Time Between Failures (MTBF) improvement of critical assets Conduct proper RCA to solve reliability issues and track actions to closure. Drive continuous improvement initiatives such as energy optimisation, steam recovery, gypsum handling, acid concentration improvements, and granulation efficiency. Implement digital tools such as AI/ML, CMMS, DCS/PLC data analytics, historian systems and predictive analytics for decision-making. Training, Skills and Talent Management : Identify the skills needed for implementation of the Maintenance Plan. Recruit the team with right level of skills and experience and put in place rigorous selection procedure. Ensure continuous training and development of the maintenance team so that they are up to date with current maintenance techniques, engineering standards, equipment maintenance requirements etc. Monitor performance of individuals and give them feedback on improvement areas and implement comprehensive performance review processes for their development. Ensure only high quality contractors are selected for maintenance services, fabrication, shutdown manpower, OEM support, and emergency support. Monitor their performance and provide continuous feedback for improvement. Turnaround & Shutdown Management : To be responsible for the planning and execution of major turnarounds (TA), shutdowns and catalyst changeouts for SAP/PAP/DAP plants. To define the budgets, timelines, manpower planning, contractor management and quality control measures in discussion with the Manufacturing Head. Ensure shutdowns are completed safely, within timeline and cost, with reliable post-startup performance. To ensure department heads coordinate with Operations, Supply Chain, HSE and Projects for seamless shutdown execution. Projects Engineering & Capex Execution To lead all brownfield and greenfield engineering projects including capacity expansion, debottlenecking, efficiency improvement and infrastructure upgrades. Prepare basic engineering, detailed engineering, equipment specifications, tender documents, technical evaluations, and vendor selections. To oversee project scheduling, budgeting, execution, supervision, commissioning and handover to operations. Collaborate with OEMs, technology licensors, EPC contractors and consultants. To ensure up to date engineering drawings, P&IDs, layouts, electrical SLDs, loop diagrams, asset registers and plant documentation. Budgeting, Contracts & Vendor Management Prepare annual engineering budgets covering maintenance, spares, shutdowns and capital projects. Establish cost saving targets annually and monitor the progress. Monitor the spending on monthly basis and control the cost of maintenance. Preferred candidate profile B.Tech. /B.E in Mechanical, Electrical, Instrumentation with 20-25 years in fertilizers/chemicals with minimum 810 years in senior engineering leadership roles Hands-on exposure to maintenance and projects in Fertilizer industry Proven track record of executing major shutdowns and capital projects. Skills / Knowledge / Competencies : Strong understanding of process equipment used in a Fertilizer plant manufacturing Acids and Phosphate Fertilizers Advanced knowledge of maintenance engineering, reliability engineering, and asset integrity Skilled SAP, DCS/PLC, AI/ML tools Expertise in project engineering, Knowledge of HAZOP,PSM, RCA, FMEA, TPM, RCM, RBI Strong understanding of utilities: steam, water, power, cooling systems Planning & execution excellence Cross-functional teamwork Vendor & contractor management Problem solving & decision-making Communication & stakeholder engagement Situational leadership and crisis management IRAMA GLOBAL

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