Ehab Sorore

Leading and Managing the following sections:
1) Utility Operation & Maintenance:
• Oversaw the operation and maintenance of cogeneration plant with capability of 175MT/hr (3 Boilers) steam generation and 22MW/hr (3 Turbines) power generation. Resolved the challenge faced 2 years ago in steam generation capacity as it was only 55% of capability and through planning and execution of the action plan, successfully achieved now 83% capacity and by Jan-25 it will be 100% capacity taking in consideration the failure won't re-occur permanently.
• Developed 4 years continual improvement plan for cogeneration plant and utilities operation (Power, Steam, NG, raw water, wastewater, waste gas) either internal or external resources from authorities to achieve maximum production of Carbon Black with optimum running cost.
• Oversaw and planned project execution to de-bottleneck steam generation capacity, which was limited to100 TPH against 175 TPH capability, in Nov-23 we achieved 145 TPH and by Jan-25 it will be completely restored to maximum design 175 TPH.
• Championed Innovative idea to increase power generation from current assets (Turbine) through increasing consumption of the extraction steam from turbine to operate equipment instead of electrical motors so that it has double impact by reducing the power consumption in equipment, in the same time will increase power generation from turbine by 3 MW/Hr through increasing the extraction. Project approved with CAPEX value $1.75M , payback is 3years, in execution phase now (will be completed in Aug-25)
• Managed the Utility KPIs to maximize the energy generation and reduce wastes such as waste gas burn in incinerators, wastewater disposal in alignment with legal requirements ,organization HSE policy and sustainability objectives.
• Negotiated contracts with energy buyer customers and could achieve ~220% increase in the steam selling price during FY24. on other hand succeeded to increase the steam export from 4 to 7 TPH through satisfying the customer requirements.
• achieved successfully to convert the net utilities revenue to be positive from power and steam capacity increase and sell, achieved in 2 years to change the company net utilities revenue from yearly loss of $900K during last 5 years to become a gain of $37K in Q1 FY25 for first time and it will continue increasing in the next years.
2) Projects Management:
• Oversaw and planned for CAPEX projects implementation for 7~9 M$ yearly to enhance the plant reliability, Availability and improvement by replacing the overdue equipment.
• Participated in development meetings for customers and business operations updates and arranged for the needful upgrades or changes required to meet the customer requirements in development of new grades needed.
• Negotiated contracts with vendors for procurement of capital equipment and projects required in manufacturing operations, ensuring best value without sacrificing quality or reliability.
• Led initiative of 12 continuous improvement projects for last 2 years and managed cross-functional teams, streamlining communication between departments for more efficient project execution. and could result in significant improvement, cost savings, future plans and waste reduction through 12 different projects to work in parallel and review the performance updates bi-weekly to report to Unit head with progress, challenges and any support needed to complete those projects.
• Oversaw successful implementation of multiple major projects simultaneously adhering strictly to budgetary constraints while maintaining high-quality deliverables.
• Enforced health and safety protocols to promote safe working environment by implementing actions and projects on priority to resolve any hazard conditions permanently.
• Oversaw a strong team from 14 engineers and 45 employees of engineering personnel.
• Oversaw Improvement of the CBFS oil loading station at port from Environment perspective by re-engineering and HAZOP study and replacement of loading system from open loading system to closed loading system eliminating any vapor escape to environment. After implemented successfully and highlighted as best practice by the third party to many companies in Petroleum sector to learn from that and my company shared that strength with other companies to adopt for their sites operation in Egypt.
3) Mechanical Maintenance:
• Oversaw the timely execution of preventive maintenance (TBM, CBM) & proper closure of all the findings without slippage to prevent sudden failure of the equipment.
• Reduced equipment downtime through preventive maintenance and root cause analysis for recurring issues.
• Oversaw planning of the daily notifications from operation, checklists and inspection activities confirming proper prioritization in place to attend the problems without affecting the production process and plant availability.
• Oversaw the yearly planned down time activities preparation and execution including turnarounds.
• Evaluate performance metrics, identifying areas for improvement and developing strategies to address them effectively.
4) Reliability and Preventive Maintenance:
• Oversaw the Preventive maintenance and inspection plans to cover all the equipment under all categories in the plan.
• Oversaw planning of required turnarounds yearly to confirm the execution within planned time and budget with the highest efficiency for equipment reliability.
Resources Management:
• Managing a strong team of 14 Engineers and 45 employees in engineering personnel by implementing company policies, procedures, work rules, and disciplinary action.
• Evaluate employees performance and timely provide needed feedback and training to ensure optimum performance through clear goals and actions for what not went well.
• Managing ~12 external contractors during major repairs , turnaround and Projects executions by implementing company policies ,Procedures and confirming the safe working and best quality of work is provided with the budget and time frame.
• Developed training programs for new employees, ensuring a skilled workforce with reduced onboarding time.

• Ensured compliance with all relevant local, company global regulations pertaining to mechanical system operations and maintenance.
• Maintained a safe working environment by enforcing strict adherence to safety policies and procedures.
• Driving the develop & Improve maintenance system to ensure availability of Mechanical equipment for production and its associated infrastructure with reliability, Lead Mechanical team to achieve the optimum Shutdown activities planning and execution, Monitor Maintenance of equipment at Port storage area including loading of CBFS oil at port area and then unloading to plant.
• Explore and arrange facility/tools/ equipment for proactive maintenance, Review preventive & predictive maintenance schedule and revise as required to improve its effectiveness and efficiency, Monitor MTBF/MTTR of critical equipment for improvement, Confirm proper analysis of breakdowns and take corrective and preventive action for non-reoccurrence, Confirm the compliance of planned shutdown maintenance activities of equipment effectively and efficiently.
• Coordinate with internal customers and ensure the compliance of non-conformances observed through the various sources of internal or external audits and plan for the Corrective and Preventive actions.
• Ensure optimum equipment life and plan for continuous improvements.
• Improved equipment reliability by implementing preventive and predictive maintenance programs to ensure all equipment categories are in TBM or CBM programs to ensure early detection of failures and to plan for the needful actions before breakdown.
• Reduced unplanned downtime of mechnnical equipment from 3% to less than 1.2% through effective maintenance systems and resolving the chronic problems.
• Maintained detailed records of all maintenance activities, providing valuable data for future planning and decision-making processes.
• Partnered with production supervisors to minimize the impact of maintenance activities on overall plant operations.
• Optimized work schedules to minimize disruption to production while still addressing critical maintenance needs.
• Cultivated a positive work atmosphere by recognizing individual accomplishments and promoting teamwork among staff members.
• Managed resources effectively, ensuring availability of spare parts and tools for prompt repairs in optimum time when needed.
• Evaluated performance metrics, identifying areas for improvement in both individual team members’ skills and overall departmental processes.
• Supervised and Assisted in the development and implementation of capital improvement projects, providing technical expertise and input on equipment selection and installation processes.
• Streamlined maintenance processes by developing and implementing standard operating procedures for routine tasks.
• Collaborated with engineering teams to identify design improvements that reduced recurring maintenance issues.
• Conducted regular inspections of equipment through TBM and CBM programs to identify potential issues before they escalated into costly repairs or safety hazards.
• Spearheaded Turnarounds and major overhaul projects, coordinating efforts between internal teams and external contractors to ensure timely completion within budget constraints yearly.
• Evaluated employee performance and conveyed constructive feedback to improve skills.
• Successfully managed budgets and allocated resources to maximize productivity and profitability.
• Assisted in organizing and overseeing assignments to drive operational excellence like 5S , Kaizen, Hazard identification and rectification and TPM.
• Initiated using industry expertise, customer service skills and analytical nature to resolve customer concerns to promote loyalty through creating contamination control program related to maintenance activities and ensured timely execution of that program to prevent any maintenance activity impact to product contamination or quality. Implemented in 2016 and till date we didn't a single customer complaint related to maintenance practices contamination.
• Experienced in carbon black manufacturing equipment: Reactors, Air Preheater , Oil preheater , waste heat boilers , Main bag filters , centrifugal fans , Pelletizers , Rotary Dryers , Microrpulverizer, agitators, bucket elevators , Screw conveyors , Belt conveyors , scalper screens , Magnetic Separators ,Storage silos, CBFS oil storage. tanks and pumps.
• Established performance goals for employees and provided feedback on methods for reaching those milestones.

• Ensure overall Safety for the maintenance work carried out.
• Ensure proper issue of PTW, PPE and scaffolding is used suitable for the job.
• Regular Meeting with Production department to discuss the performance, issues related to maintenance need immediate or long-term action as per the issue urgency & the production plan requirement.
• Managed mechanical budget plan and execution.
• Managed Departmental Manpower resources planning & skills development (by Training, directing & coaching).
• Managed root cause analysis of Failure and supervision of the preventive action execution and review if any fine tuning required to confirm non-reoccurrence.
• Led the train. motivation of mechanical team for successful team work and efficient co-ordination with other departments to achieve the company goals.
• Oversaw the annual shutdown planning & execution, Ensure Preventive and Predictive maintenance schedules are adequate and covering all equipment.
• Timely rescheduling is done as necessary based on the production plans.
• oversaw usage of SAP as a tool to ensure the effectiveness of the PM schedules and maintaining the equipment history and availability of critical spares required for activities.
• Ensure usage of monitoring devices for rotary equipment like vibration and temperature monitoring to early detect any abnormalities.
• Stationary equipment hydraulic tests, thickness measurements, Safety test and certification of rigging tools are properly planned and executed on schedule to prevent any sudden failure or safety incident.
• Plan & Ensure Implementation of major improvement projects related to the Environment, Safety, yield and productivity in the plant.
• Led the line maintenance in-charge engineers to achieve the work by directing and coaching to ensure the departmental systems sustainability to achieve the company goals.
• Identified areas for improvement within the department, implementing strategic initiatives to address gaps in performance or resources.

• Assisted in estimating the yearly mechanical department budget and management.
• Planning and Coordination with the Production team as per production plan to ensure maximum availability of the equipment.
• Ensured complete analysis of the root cause of failures and implement corrective and preventive actions.
• Implemented major improvement projects related to environment, Safety, yield and productivity in the plant.
• Planned major Overhauling planning (Preparation of targets and resource mobilization as per activity schedules including manpower allotment , Spares management ,Contractors allotment and their mobilization, Cost estimation.
• Calculate and record MTBF and MTTR of failure critical in nature and implement and assist in the analysis to plan corrective and preventive actions.
• Assist in successful alignment and implementation of 5S, WCM, TPM and ISO-16949 systems and update procedure from time to time to confirm the compliance with system.
• Develop local vendor for spares and fabrication of items related to equipment and stationary items as we have most equipment are imported from outside.
• Set guidelines and direct Purchase department procurement by correctly specifying spares for alternate vendors and also identifying, developing and recommending vendors for services used in plant during maintenance.
• Ensure safe working conditions in the mechanical department and prepare SOP for jobs executed by my team members.
• Contractor Development and Safety management to ensure control, coordination between the contractors during the plant shutdowns and major repairs for safe working.
• Equipment critical, Insurance and non-critical spares control (Indenting the required spares, selection of the technically correct spares, critical stock availability.
• Ensure target commitment by following up the maintenance activities execution with the mechanical engineers & Maintenance foreman to confirm updating of the planned (time based) preventive maintenance schedule for all equipment to minimize problems.
• Oversaw shutdown scheduling to ensure timely and appropriate solutions are adopted avoiding major breakdown,
• Mentor and train mechanical staff, prepares on job training programs to spread the knowledge among the staff.
• Evaluated performance of staff and recommended promotion, additional training or termination based on goals and performance.
• Prepares employees’ safety procedures and makes sure that these procedures are followed.
• Coordinated between mechanical and Production department to confirm the attendance of all targeted maintenance activities.
• led the execution of ISO, TPM and TQM procedure execution.
• Safety & Health committee team member.
• led of the mechanical maintenance workshop all the fabrication & repair job execution on time and with the proper technical quality.
• Confirmed the in-house fabrication quality of the required equipment (Metal sheet work) as per the standard drawing and the technical specs.
• led daily (15 min) meeting morning around the workshop toolbox and supervise the manpower allocation on job , we discuss any problem if there and give tool box talk for the day activities safe working.
• led the preparation, planning and execution of the CAPEX projects and best practices in maintenance shared by other sites.

• Performing & Repairing of Rotary Equipment such as: Pumps, Screw Compressors, Process Air Blowers, Fans, Palletizers, Pin mixer, Rotary Dryers, Bucket Elevators, Magnetic Separators, Scalper Screen, Screw Conveyors, Belt Conveyors, Stretch Wrapping Machine, Airlocks (Rotary Valves), Performing coupling Alignment using Dial Indicator (Also got training on Laser Alignment.), Preparing technical data for equipments including drawing of parts (using AutoCAD.), Participate in Overhauls planning ,material preparation & Manpower distribution, Ability to distribute the work among technicians & Supervisors, Attending for any Mechanical problem Inform from Shift In-charge, Control Spares Consumption & raising the purchase requisition of the Required Spares to HOD, Participating in Preventive / Predictive / Reactive Maintenance activities, Participating in organization activities ( TPM , TQM , WCM), Overall vibration data collecting & identifying results which is the cause of Abnormalities, Scanning the distribution of the temperature of a machine (Stationary – Rotary) using INFRARED CAMERA(Thermograph technique.), Performing & Repairing of Stationary equipments such as: Heat Exchangers, shell and tubes type, Reactors, Bag Filters, Silos, Jumbo Machines, Preparation of fabrication drawings including metal sheets calculations and Bill of Materials (For Silos , Tanks ,…etc.), Forklifts Maintenance

• Supporting Actions/ Tasks: Develop & Improve maintenance system, Ensure availability of Mechanical equipment for production and its associated infrastructure with reliability, Lead the SH Mechanical to achieve the optimum Shutdown activities planning and execution, Monitor Maintenance of equipment at Misr Petroleum Co (Port) storage area including loading of CBFS at Misr Petroleum area and then unloading from above to plant, Explore and arrange facility/tools/ equipment for proactive maintenance, Review preventive & predictive maintenance schedule and revise as required to improve its effectiveness and efficiency, Monitor MTBF/MTTR of critical equipment for improvement, Confirm the analysis of the breakdowns and take corrective and preventive action for non-reoccurrence, Confirm the compliance of planned shutdown maintenance activities of equipment effectively and efficiently, Coordinate with internal customers and ensure the compliance of non-conformances observed through the various sources and plan for the Corrective and Preventive actions, Ensure optimum equipment life and plan for continuous improvements