Ali Mohamed Afify

• Successfully integrated an advanced heating monitoring system into the factory's operational infrastructure. The new system enabled real-time tracking of heating parameters, significantly improving efficiency and reliability by reducing unexpected downtime and enhancing system diagnostics.
• Spearheaded the upgrade of a critical, outdated dosing system to a modern and more reliable alternative. This involved coordinating with cross-functional teams, overseeing the installation process, and conducting rigorous testing to ensure the upgraded system met operational standards.
• Established a preventive maintenance program for electrical systems, leveraging predictive analytics to schedule maintenance proactively. This led to a [specific reduction] in equipment failure and downtime, improving overall equipment effectiveness [OEE].
• Create and implement electrical designs for industrial equipment, systems, and machinery, ensuring they meet both company requirements and industry standards.
• Oversee the installation and commissioning of new electrical systems and equipment, including transformers, generators, and motors, ensuring they are fully operational and meet performance standards. Responsible for preparing Functional Design Document.
• Perform regular maintenance and troubleshooting of electrical systems, identifying and resolving faults quickly to minimize downtime and prevent production disruptions.
• Develop and integrate automation systems, such as PLCs, SCADA, and DCS, to improve the efficiency and accuracy of manufacturing processes and reduce manual intervention Work on refining the Work Order processes, PO Voucher Tolerance adjustments, modification of Cycle Count Process based on the changes in ABC analysis, custom aging report and Margin Checks.
• Ensure all electrical installations comply with local and international safety standards (e.g., IEC, NEC) and regulations. Implement safety protocols, conduct risk assessments, and promote a safety-first culture within the team Created data for the testing and configuration of the objects.
• Plan, execute, and manage electrical engineering projects, including budgeting, scheduling, and resource allocation. Coordinate with cross-functional teams to ensure projects are completed on time and within budget.
• Prepare and maintain detailed documentation, including technical drawings, wiring diagrams, and reports, to ensure all engineering work is traceable and compliant with regulatory standards.
• Work closely with vendors and suppliers to source high-quality electrical components and materials, negotiate contracts, and ensure timely delivery for project success. Pre-Upgrade activities.
• Train and mentor technical staff on the operation and maintenance of electrical systems, enhancing their skills and knowledge to improve team efficiency.
• Gather and analyze data from electrical systems to identify patterns, troubleshoot issues, and make data-driven decisions for optimization.

• Reduced downtime through efficient troubleshooting and root cause analysis of equipment failures.
• Developed preventive maintenance schedules to minimize downtime and optimize performance.
• Performed root cause failure analysis on critical equipment, leading to more effective preventative measures.
• Maintained strong relationships with vendors and suppliers, securing high-quality parts at competitive prices for the company.
• Experienced in preventive, corrective, and predictive maintenance of BOPP film production lines.

Technical & Detailed:

• Skilled in troubleshooting, repairing, and optimizing BOPP film extrusion and stretching line equipment to minimize downtime and ensure consistent production quality.

Achievement-Oriented:

• Conducted maintenance and reliability improvements for BOPP manufacturing lines, integrating systems such as Thermo Fisher profile gauges, MERO corona treatment units, and Schenck dosing systems to achieve high efficiency and reduced defect rates.
• Experienced in operating and maintaining Thermo Fisher™ thickness/profile measurement gauges for BOPP film production.
• Skilled in calibration, troubleshooting, and optimization of Thermo Fisher profile gauge systems in industrial manufacturing environments.
• Experienced in operating and maintaining MERO corona treatment systems for surface activation in BOPP film production.

Technical & Responsibility-Focused:

• Proficient in setup, calibration, and maintenance of MERO corona treatment units to ensure optimal surface energy for printing and lamination processes
• Experienced in operation and maintenance of Schenck dosing and weighing systems for precise material feeding in industrial processes.

Technical & Responsibility-Focused:

• Proficient in calibration, troubleshooting, and optimization of Schenck gravimetric dosing systems to ensure accurate material flow rates and production consistency.
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• Managed a comprehensive industrial automation project in Egypt, overseeing all aspects from planning to execution.
• Successfully commissioned the PIEX line dedicated to the fabrication of water pipes, ensuring full operational readiness and optimal efficiency.
• Programmed and upgraded plastic cutting machines utilizing Delta CPU technology.
• Led the installation and startup of the GEA Suspension Plant for GlaxoSmithKline in Cairo, focusing on instrumentation.
• Designed and installed electrical panels for K-FLEX in Cairo.
• Managed the installation and commissioning of a polyethylene line in Poland for K-FLEX, employing a PLC S7-1200, HMI TP1200, and G120 VFD.
• Oversaw the installation and commissioning of the L. LUNARDON line in Poland for K-FLEX, utilizing OMRON technology, including HMI and VFD systems.
• Enhanced and modified the programming for Mercedes-Cairo using SCL programming language with Simatic Manager software.
• Directed the installation and commissioning of the PEX line for K-FLEX in Poland.
• Executed hardware and software modifications for a cutter machine to facilitate operations on the Italian line (May 2022) for K-FLEX.
• Served as the lead engineer responsible for the transport, installation, and operation of two large insulation lines for K-FLEX in Poland.
• Modified, installed, and programmed a crane for the Egypt Metro project using the TIA Portal 16V and FB PLC S7-1200 with KTP 700 BASIC HMI.
• Modified, installed, and programmed a burger machine for the Fresh Food Factory project using the TIA Portal 16V and Ladder PLC S7-1200 with KTP 400 BASIC HMI.
• Creating systems to automate industrial processes, using PLCs, SCADA, and HMI.
• Writing, testing, and debugging programs for PLCs and SCADA.
• Analyzing workflows and identifying opportunities to improve efficiency and productivity.
• Diagnosing and fixing issues in automation systems to reduce downtime.
• Applying smart technologies to optimize data collection and machine-to-machine communication.
• Working with production, maintenance, and quality teams to improve manufacturing processes.
• Ensuring automation processes meet safety and regulatory standards.
• Overseeing automation projects, from initial planning to final deployment, within budget and on time.
• Preparing detailed system and process documentation for training and compliance.
• Evaluating potential hazards related to automation systems and implementing mitigations.
• Setting up and troubleshooting industrial network communications.
• Assisting operators and technicians with system understanding and troubleshooting.