Abdou Hussein

• Driving a Zero Harm Today culture and ensuring applicable safety and environment systems and procedures and the establishment, communication and monitoring of KPI's to ensure agreed performance
• Driving a cultural improvement initiative that sustains safety, performance and engagement amongst the team Management of procurement procedures
• Implement continuous improvement and capital projects
• Minimizing cost by monitoring and reporting manufacturing KPIs, developing and implementing improvement plans, ensuring plant operates efficiently, minimize wastage and management of overtime
• Maintaining a highly-skilled, productive workforce by individual development and coaching and training of shift and day work employees to in turn motivate the workforce by involving them in decision making processes where appropriate
• Management of raw material, work in progress and finished goods and working with Sales and logistics to meet market demand
• Prepare annual and monthly production budgets
• Coordinate and manage the production on a daily basis for the availability of the required product within the specified time, quality, and cost
• Monitor and control milling operations and processes
• Ensure protection of environment and the use of personal protective equipment Managing of the production of cement types: OPC, SRC, white cement , slag GGBS Plan technical shutdowns with other departments
• Define an audit plan and supervise the audits to detect irregularities and find potential improvements
• Ensuring audits and studies are documented and shared
• Contributing to fuel cost optimization (optimization of lowest fuel cost) by ensuring (optimizing) process condition (STEC) which allows a maximum utilization of alternative fuel and raw materials
• Identifying actions targeting the reduction of overall plant power consumption (SEEC)
• Identifying and preparing for mid and long terms process (PDP) and environmental improvement needs
• Manage the utilization of manpower, mobile equipment, fixed assets and contractors
• Identify specific developmental needs and gaps of the operating staff in the department
• Train and develop the operating staff to provide specific plant knowledge Control and guide the daily work
• Implement (SOPs), reporting functions, and work instructions for optimizing the process chains

Project &Achievements:

• Feasibility Study for Installing 1.2 million ton balls mill grinding unit (4.6x15.6 m) for OPC & SRC grinding
• Feasibility Study for Installing 50 tph ( 2.6x20m) rotary dryer for GGBFS For moistening releasing using AF fuel
• Conversion of OPC grinding mill (50 tph ) into white cement and GGBFS Grinding ( 30 tph ) by shorten the first chamber length from 4.46 to 2.46 m
• Separator reconfiguration by utilization primary and secondary air, separator is being useful from scratched after modification
• Replacement cost of around 100, 000 USD was being saved
• Employing KPI's for production and maintenance (Provide actionable information
• Provide a platform for future strategies
• Empowers people to improve their own personal performance along with the organization)
• Increasing airside canvas life time by installation automatic nibs trip in 3 mills circuit
• Evaluation of Grinding Aid impact, accurate overview how much savings we incur when using certain type of grinding aid
• Cement quality improvement (10-15%) in the 3, 7, and 28 day strength
• Savings of raw material cost: 0.15 Kd/ton Savings on Power Consumption: 4-6 kWh/ton
• Controlling the Cement Product temperature by using fresh air @ separator without cement cooler ( Controlling the mill outlet temperature -Controlling the final product temp
• By cooling the mill circuit Controlling the final cement product inside the silo)
• Implanting audit kits for cement balls mills
• Grinding Media (Balls) Consumption and low Wear rate for GGBS grinding (Blaine 6000 cm2/g less than 200 g/ton
• New mill and bags packers commissioning and stabilization

General work:

• Customer and product’s support for related matters quality or delivery , maintain the quality delivered on time
• Responsible all product approvals from all the governmental societies (Public authority for industry & Ministry of Defense &
• Ministry of Public Work & Public Authority for Housing Welfare)
• Guarantee compliance to the Kuwaiti authorities’ quality ASTM and KWS GOS standards and metrics
• Responsible all company files (Product and company broachers & product data sheet and MSDS )
• Production plan vs sales budget and total achieved
• Cost controlling per ton produced and sales
• Responsible for IMS ISO (9001:2015 & 14001:2015 & 18001:2007 ) auditing and files Responsible for all electronic service with the Public authority for industry for industrial procedure ( product approval , adding new material , spare , Customs exemption,) also for the Environment Public Authority
• Responsible for all the operation and maintenance for the ship unloading system and loading for all bulk material
• Responsible for all the company fleet silo truck & half lorry and dump truck register and port permits Cost control for all shipment ( CIF , Shipments clearing , DA charges , global charge , stevedoring charge , transportation )
• Responsible for plant OEE performance indicator and to reduce all operation cost, and full authority on recruiting selections, salary ranges, grades…etc
• Senior Process Expert at Online technical support
• Flsmidth Operation & Maintenances Technical Centre
• PLM Business Performance, Worldwide

• Implements the best practices for online support
• Including production and process testing Procedures and condition at all
• Operation & maintenances projects of FLSmidth.10 cement lines in Different countries (Egypt, Libya, Tunisia, Angola, Iran)
• Support Group Companies to efficiently design and operate their cement plants and in building of New plants in the field of cement pyro process and grinding
• Evaluate measuring results and advice for improvements to maximize performance
• Develop grinding improvement initiatives and set plant specific targets for cost reduction
• Evaluate operational coefficients
• Optimize production facilities
• Provide process-related and operational techniques for environmental impact reduction
• Perform training and knowledge on operational techniques (Trouble shooting), process related new
• Development in grinding
• Initiate corrective actions on non-performing mills and kilns
• Train and coach operational personnel in production knowledge
• Support acquisition projects by evaluating cement plants and supporting technical due diligence
• Support and fertilize group-wide knowledge management in the field of production and process Engineering
• Trouble shooting &Data analysis & RCA analysis
• Continuously monitor and analyses data process/equipment performance
• Support group plants by specific performance improvement programs
• Creating &monitor and analysis KPI / tracking improvement tools for 10 cement plant
• Responsible for cement plant audit (grinding optimization, Energy and cost saving)
• Improved operations through consistent hard work and dedication.
• Drove operational improvements which resulted in savings and improved profit margins.
• Managed team of employees, overseeing hiring, training and professional growth of employees.

• Attend the Fábrica de Cimento do Kwanza Su (FCKS Sumbe plant) First Line Commissioning and PGT, Full monitoring of developing, whether at the CCR, or Field, analysing Testing Progress of the Plant, ONE Production Line, Design specification-
• ATOX 45 (320t/h), Kiln-Cross bars Cooler (4200 t/day), 2 Cement Mill (250 t/h), Ventomatic Packing system (10000 t/day),
• Submits, Reviews and analyses production and operational reports and trending to determine
• Causes of nonconformity with product specifications, and operating or production problems
• Develops operating methods and procedures designed to eliminate operating problems, as well as to improve product quality and productivity
• Consults with engineering personnel relative to modification of machines and equipment in order to accomplish these objectives
• Keeps abreast of new technology in the industry
• Provides technical support for process control and operations of manufacturing equipment
• Conducts a daily process equipment operational inspection
• Briefs the Plant Manager regarding Daily operations, personnel matters and changes
• Create new stuff, train them, prepare all process documents, and follow up the plant commission
• Ensuring necessary manpower, competence, skill, knowledge, plant and tooling required in order to achieve production targets
• Refractory work:
• Visual & borescope inspection of all kilns, preheaters, cooler etc., based on requirement for installed refractory materials during operation
• Supervises and coordinates activities of workers engaged in installation of refractory products, such as brick, and castable
• Observes operation of machinery and equipment, such as kilns, preheaters and cooler temperature profile to detect malfunctions
• Refractory maintenance job is any refractory repair/replacement performed in all equipment, including:
• Provision and Installation of lighting in the equipment where refractory jobs will be performed
• Mobilization & demobilization of equipment, materials, consumables and manpower
• Repair & rebuild existing refractory linings or construct new lining upon request, using Brick laying, Casting, and Gunning,
• Pumping, Shotcrete or any other applicable technique in the Travelling Grates, Rotary Kiln, Process Ducts, Annular Cooler,
• Grinding & all other equipment
• Preparation and grinding of surface for welding of anchors, ferrules and plate angles necessary for refractory job

• KPI evaluation and setting improvement targets
• Responsible for planning, monitor and complies with Production Plan, controlling the entire Productive Process on a day to day basis
• Coordinate between Process In-Charge and inters departments for achieving the goal based on the Available resources
• Work instructions to Shift In-Charges and follow-up the same for the smooth operation of the plant
• Calculate and evaluate Heat and Mass balance for raw grinding, Pyro process and Cement grinding sections
• Monitoring the Specific power and fuel consumption on regular basis and making plan to achieve the target
• Preparation of production plan on a daily, weekly and monthly basis
• Preparation and follow up of budget plan every year, including plant KPI’s
• Trouble shooting the plant operation in coordination with the inter department personnel
• Planning of the yearly shutdown in terms of refractory (bricks and castables) in coordination with Maintenance
• Create and implement the process routines
• Comply with Quality targets in all productive process
• Monitoring the pollution control activities in coordination with HSE Department
• Co-ordination in stoppage and maintenance plan, from process department side
• Propose improvements in the Productive Process in order to optimize costs
• Perform any extra duties assigned by the Process In-Charge

• Supervising the operation at the different plant sections during shift
• Follow up raw material, fuel oil and empty bag delivery during shift
• Coordinate plant machinery stoppages and production of proper quality clinker
• Supervise cement and clinker dispatch during shift
• Cooperation with mechanical and electrical shift engineers for trouble shooting and problem solving
• Prepare production event reports during shift and fill shift log book
• Ensure that all activities are carried out according to the safety procedures
• Optimize the heat and power consumption and maximize the output of major equipment
• Make a control on man power and make dispersion in plant
• Control to ensure that product meets required specifications
• Preparation of production plan on a daily, weekly and monthly basis
• Preparation and follow up of budget plan every year, including plant KPI’s
• Troubleshooting the plant operation in coordination with the inter department personnel

• Attend the Line Commissioning and PGT, Full monitoring of developing, whether at the CCR, or Field, analyzing Testing
• Progress Of the Plant, ONE Production Line, SINOMA Design Operation process for The kiln (with 4stage and in line calciner) using PLC and operation System, and follow up field work
• Checking lab
• Analysis (ARL, QCX operating system works on line with process
• Control to ensure that product meets required specifications
• Obtaining the trends, charts and process data for any measuring or controlling point and analyzing them to specify the problems
• Calculate and evaluate Heat and Mass balance
• Raw grinding, Pyro process and Cement grinding sections
• Monitoring the Specific power and fuel consumption on regular basis and making plan to achieve the target
• Member of upgrading line and increase the capacity by changing the system of kiln feed Modification, Troubleshooting)

• Supervisor for Vertical roller mill (AT OX 25), two slurry tube mills, Cement tube ball mill, and follow up field work
• Obtaining the trends, charts and process data for any measuring or controlling point and analyzing Them to specify the problems
• Monitoring and adjusting the process parameters (temperatures, pressures, flow rates, levels, etc.) For Raw Mill (ATOX 25) and its auxiliaries
• Monitoring the pollution control activities in coordination with HSE Department
• Monitoring the Specific power and fuel consumption on regular basis and making plan to achieve the target
• Member of commission team of line two (Commission, Erecting and Troubleshooting)
• Coordinate plant machinery stoppages and production of proper quality
• Create and implement the process routines
• Comply with Quality targets in all productive process