FAIZAL SAFARULLA

An experienced Engineering / Maintenance professional with over nine years of experience at Al Ain Farms (Formerly Al Ain Dairy), a prominent dairy and poultry producer in the UAE seeking a challenging engineering position working with technical projects, manufacturing processes or maintenance functions that will maximize my extensive experience in these areas.

Assistant Maintenance Manager

Al Ain Farms (Formerly Al Ain Dairy)                                        Dec 2020 - Mar 2023 (2 years 4 months)

• Managed maintenance programs for production facility responsible for the manufacture of various dairy & juice products like fresh milk, yogurt, juice, powder, butter, UHT, etc. resulting in a 12% reduction in equipment downtime and a 10% increase in overall production.
• Led a maintenance team of 20, overseeing the completion of preventive maintenance tasks monthly, resulting in a 92% adherence to maintenance schedules.
• Optimize machineoutput, increased OEE, implemented efficiency-enhancing projects,resulting in cost savings and reduction in energy consumption,
• Managed CAPEX planning, OPEX budgeting, 5S implementation, manage key performance indicators (KPIs).
• Coordinate and oversee repairs,renovations and maintenance projects in a timely and cost-effective manner.
• Prepare specs for new equipment, raise PR, request RFIs/RFQs, perform technical analysis,cost analysis, competitive analysis, Bill of Materials,etc. as per requirement.
• Create maintenance plans, schedules and generate work orders.
• Management of spare parts inventory and handling of petty cash.
• Screening, Shortlisting & Interviewing of candidates for maintenance relatedjob functions.
• Vendor Evaluation and development.
• Deal with NCRs, participate in GEMBA walks,quality audits and expedite closeoutof any findings.
• Participate in FAT & SAT for new equipment, Lead Installation, Assembly& Commissioning of new equipment.
• Design / approve changesto process lines / equipment to suit production of new products or as per PID
• Facilitated trialruns for packaging materials and developnecessary changes when required.
• Manage SLAs to ensurea full compliance with the contractual aspects.
• Manage externalvendors and contractors to ensure qualitywork and adherenceto budget.
• Lead Installation, Assembly &Commissioning of new equipment / trial run for packaging materials
• Liaise betweenproduction team and OEM suppliers / contractors for services and maintenance relatedactivities.
• Support proactively all EH&S procedures and policies.

  Supervisor / Team Leader- Plant Maintenance

Al Ain Farms (Formerly Al Ain Dairy)                                 Feb 2017 - Dec 2020 (3 years 11 months)

• Experienced in troubleshooting of Mechanical, Electrical, Pneumatic & Hydraulic equipment.
• Experienced with APV / SPX / TetraPak production plants
• Experience in maintenance on Tetra Therm Aseptic Drink,VTIS, Tetra ThermLacta Plant, SPX Processing Plant, AlSafe, Tetra Alex & SPX Homogenizers, Separators of Seital, Westfalia, Andritz and Bactofuge.
• Experience in maintenance of Plate & Tubular Heat Exchangers, CIP Plants, PowderPlants.
• Experience in maintenance of Vertical Form Fill Seal auger machine for pouch/sachets, multi head FFS yoghurt filler and milk pouch filler.
• Supervised skilled maintenance technicians, scheduled work hours, resolved conflicts.
• Arrange sparesfor service as per preventive maintenance schedule and verify taskshave been completed.
• Assign and direct the work of skilled and unskilled staff performing buildingmaintenance and repairactivities.
• Monitor installation activities at site and post update on project completion.
• Assist 3rd party contractors during calibration of equipment.
• Oversee installation, repair and maintenance of HVAC equipment.
• Breakdown handlingof VFD’s by changing the preinstalled programparameters or by replacing the power cards.
• Maintenance & troubleshooting of processcontrol systems including PLC, VFD’s, Transmitters and flow controls.
• Wiring / modifying panelsas per electrical diagram or as per requirement.
• Preparing and updating FSMS documents and furnishing duringinternal and externalaudits.
• Prepare and maintain completeequipment list and machine historycard and update in accordance with preventive maintenance schedule respectively.
• Maintain accuratedocumentation of maintenance activities using computerized maintenance management systems(CMMS).
• Conduct trainingsfor new operatorsand technicians for the operation of Domino & Hitachi printers.

  Junior Mechanical Engineer

Al Ain Farms (Formerly Al Ain Dairy)                                 May 2013 - Jan 2017 (3 years 9 months)

• Handling of all repairand maintenance duringrespective shift
• Breakdown handlingof mechanical equipmentthat includes Pumps, Sanitary Valves,motors, gearbox.
• Maintenance of bottle fillers,cup fillers, tub fillers, air rinsers, bottleunscramblers like FOGG,FILMATIC, DAWSON, INDEX6, TREPKO, PRIMODAN, DELMAX, POSIMAT etc.
• Operational knowledgeand maintenance of GEA PowderPlant Gea Drier (10Kg/Hr.) and Gea FF Evaporator.
• Responsible for recording engineering records and furnishduring audits. (ISO 9001:2008 &22000:2005).
• Mechanical team member for erection and installation of Juice & UHT Plant (In liaisonwith TETRAPAK).
• Team member in erection,installation and commissioning of GEA Camel Milk Powderplant.
• Team memberin installation and commissioning of TREPKO 232·1K,TREPKO 234KS yoghurtcup & tub fillers.

Helped in other repairsand maintenance as needed.

University of Kerala

Bachelor of Technology (B.Tech.), Mechanical Engineering

2007 - 2011