AMR GAAFAR

• Responsible for research, design and full development of a range of new and customised cutting-edge electromechanical products for AC/DC Railway Equipment, taking projects from initial conceptualisation right through to detailed design, industrialisation, prototyping, testing, production, FAIs, delivery and after-sales support. List of products include AC Vacuum Circuit-Breaker with Grounding-Switch (MACS-GS), Load-Break-Switch (LBS), Roof Switch (RS), Disconnector Switch (SWS), Earthing Switch (BTE) and Indoor Switch (IS).
• Designed detailed CAD models for full products', subsystems, components and structures, worked with Audros & Oracle, carried numerous engineering calculations and simulations such as fault-level, magnetics, BIL withstand, temperature rise, FEM mechanical stress analysis and electromagnetic short-circuit force simulations.
• Led electrical contact and interlocking systems development as well as multi-physics simulations and OpenProject within the company's offload department and assisted onload department.
• Evaluated projects feasibility based on design requirements and challenges against expected lead time with consideration to estimated NRC budget, RC and potential ROI.
• Initiated, managed and delivered projects with detailed technical and operational direction in project challenges, identified plans and resources required to meet project goals and objectives, managed costs and monitored performance actively to identify risks, areas of improvement and necessary corrective actions.
• Tracked project and team members performance closely, suggesting and implementing actionable improvements with aid of automated processes and project model strategies to increase research, design, production, quality and testing efficiency as well as widening project team capabilities to meet business objectives; helping reduce costs and improve efficiency of engineering teams.
• Communicated directly with customers' engineering technical board, managed and completed project phase reviews, meeting project deliverables according to deadlines and ensuring successful execution.
• Collaborated with cross-functional teams to conceptualize and refine product concepts, leading numerous design reviews, coordinated to resolve project issues and mitigate risks, conducted technical evaluations of engineering designs and test results, trained/mentored junior engineers providing guidance & direction.
• Met design specifications for functional prototypes, assisted production with preparing prototypes and developing efficient production processes.
• Led several investigations and completed product type-tests at the company's premises in Manchester, Czech Republic and Switzerland and externally at other test facilities i.e. IPH, Berlin.
• Communicated at all levels across multiple sites, collaborating with other departments to facilitate successful project completion, coordinated and maintained relationships with Procurement team and internal/external suppliers to facilitate timely delivery of high-quality components.
• Initiated & managed ECR/ECOs, liaising with several departments to accelerate the process, provided technical support to Quality team, leading failure assessments, assisting with NCs, coming up with and actioning rapid reliable long-term solutions and implementing QC processes.
• Drafted documentation detailing design requirements, technical specifications, procedures, risk analysis, decision matrices, project outcomes and assisted with MTBF/MTTR and device manuals.
• Developed and documented comprehensive engineering procedure and processes for all projects in compliance with engineering standards.
• Presenting to board members, executive management and stakeholders, in UK & Switzerland, detailed reports and presentations on engineering activities and findings, scheduling and facilitating meetings to discuss deliverables, deadlines and conflicts, identifying outcomes, insights, lessons learnt and future suggestions.

The Knowledge Transfer Partnership (KTP) is a European leading programme helping businesses to improve their competitiveness and productivity through the better use of knowledge, technology and skills that reside within the UK knowledge base. Under Innovate UK, I have had two roles:

• Electromechanical Design Engineer to design and develop medium-voltage Contactors and Circuit Breakers from concept to delivery at Baldwin and Francis Ltd in partnership with Materials & Engineering Research Institute, Sheffield Hallam University, 2,5 years contract (01/2015 to 06/2017).
• Robotic Process Automation Engineer to introduce lights-out CNC machining capability at Produmax Ltd in partnership with The Institute of Design, Robotics and Optimisation, University of Leeds, 6 months contract (07/2017 to 01/2018).

Electromechanical Design Engineer

The aim of this project is to design and manufacture reliable, innovative, compact/slim and efficient medium-voltage Contactors and Circuit Breakers. Main duties included:

• Conducting a wide research to select the optimum cutting edge materials for the electrical contacts (low chopping current, low contact resistance with expected contact force, high erosion resistance, low probability of welding and sticking, and, last but not least, good mechanical strength throughout its electrical life), conductors (High conductivity), insulators (High electrical resistivity, dielectric strength and arc resistance) and actuators with the aid of CES GRANTA Material Selector and investigate the impediment of using modern manufacturing techniques i.e 3D Printing & DMLS (Direct Metal Laser Sintering).
• Developing optimum configuration of the electromagnetic and mechanical elements to achieve the most compact actuation mechanism in respect to the vacuum interrupter geometry; This includes magnetic circuit design, coil design and associated control and sensing circuitry, magnetic material specification and a compatible mechanical actuation components to achieve a force displacement profile consistent with the characteristics of the vacuum interrupter selection to give optimum performance.
• Designing and modeling the various ratings of the contactors and circuit breakers using CAD facilities and interfacing the 3D CAD models with SolidWorks and ANSYS Multi-physics (Maxwell and Mechanical) to undertake transient FEA/Fatigue, thermal and vibration analysis to ensure reliability under thermal, electrical & actuation loads.
• Manufacturing prototypes, developing testing protocols with due regard to the British Standards i.e BS EN 62271 and other relevant standards.
• Performing various tests on the built prototypes to ensure product’s reliability for one million operations; Tests include; Short Circuit, Making & Breaking, Mechanical Endurance, Temperature Rise and Vibration Tests.

Robotic Process Automation Engineer

The aim of this project is to help partner business introduce lights out technology for their CNC Machines in line with Industry 4.0. Main duties included:

• Characterisation and analysis of current manufacturing processes and techniques of measurement, using this outcomes of this review to suggest changes to be tried and implemented.
• Developing and evaluating additional sensing technologies, methods for coding operations on CNC machines and techniques to interface with external signals and sensors.
• Data collection from new sensors; Qualitatively and quantitatively evaluate the success of the new sensing methods and processes.
• Directing changes on site, reporting results and preparing future planning for site management.

• Designed single-line diagrams for small/medium Power Generation projects and examined all CAT’s heavy machines technically including Excavators, Loaders, trucks, Generators, etc as I was involved in inspecting several hands-on operations on both mechanical and electrical applications.
• Visited customers sites and wrote technical reports based on customer's technical requirements (Load increase, maximum allowable current, etc.) and current plant functionality & conditions.
• Reformed surplus parts inventory based on technical specification by introducing a database software designed to decrease volume of inactive stock held by the company, reduce provisions made for holding stock, draw new and returning customers and produce a virtuous marketing material using product bundling technique.

• Worked with Engineering department in designing shop drawings prior to submission to Consultant and issuance to site using AutoCAD Software.
• Inspected MEP installation and adherence to the approved shop drawings, Directed Construction personnel to rectify defective works and presented at inspection with Engineering Consultant and instructed construction personnel accordingly.
• Examined the Drainage system, water supply network including booster pump and water tank, HVAC system including packed unit installation, split A/C and Liquefied Petroleum Gas systems.
• Checked the sub-main distribution board and final distribution board installation with roof cable containment, Lightning system, Extra Low Voltage (ELV) system for automatic reading (AMR) for power and water utilities and Optical Network (ONT) system; Ethernet & phone.