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Click here or scroll down to respond to this candidateDeyaaeldin Metwalli. US citizenDallas,TXPHONE NUMBER AVAILABLE EMAIL AVAILABLEObjective Seeking advances challenges, innovations, as a combination of Quality and mechanical power engineering.Core Competencies:Solar Module Manufacturing and new plant qualification, start up.Micro inverter for solar panels manufacturing.Electrical power plants Steel Fabrication and welding and erection.Electronic Boards SMT, PCBA:THT, ICT, Carousel, Potting, USW, HT, GT, X-Ray,C3 testing and Ionic Chromatography, ESD control.Automotive Aluminum Casting, Plastic Molding.Fenestration: energy saving glass manufacturing.Medical device Process and design Validation, Validation Protocols.-Lean methodologies,Six-sigma, Continuous Improvements.-QMS, NPI, PPAP, DFMEA, PFMEA, APQP AND MSA, Minitab.-Mechanical Design: Auto-cad, Pro-E, Solid-works.GT&D.Key Accomplishments:-led cross functional team of engineering, IT, manufacturing and operation six sigma projects to redesign master Mfg sheets that completely eliminated process failure and production delay and material waste of total saving of 700K$.-Reconstructed gaps and value mapped the quality process that improved the speed of production that could have been reducing working hours.-lead plant transfer Validations and NPI of new production.-created Kaizen program and led implementation and execution.-led training programs and established training centers.-PLC modified Poka yoke for process failure that led to performance improvement 60 %to 90%, and saved at least 700k$.-led mega projects from fabrication to erection and commissioning.-Multi-discipline electro-mechanical design solutions to design or modify current processes to eliminate Process failure PFMEA.Education Zagazig University, Egypt - B.S., Mechanical Power and Aerospace Engineering 2001Work Experience5/23 to present Quality engineering supervisorCanadian solar dallasLead the quality engineering team of engineers, supervisor and techs. to start up and operation for the new solar plant in dallas.*arranged for the entire plant measurement tools calibration.*Setting up the IPQC lab and gel content test lab.*Trained on stringers pull force test and VMM, JB and potting.*set up the ESD control.* prepared entire process product tolerance gap chart.*prepared the quality SIP work instructions.Training production on electroluminescent criteria for stringers and*pre -EL and post EL and elimination of misjudgment that lead to MRB*Worked with cross functional team on Process improvement projectsfor cell loss and module rework reduction.Lead the 2TP trail runs and improving the production .Daily follow up on quality performance at improving yield .AccomplishmentPut solutions for persisting modules quality issues related to machines and reduced the rework at pre-el by 35% load reduction and at stringer increased the rework rate by 20%.Introduced innovative best practices for strings manual handing during repair to avoid Ribbon bending or cell offset that leads to string overlap. Saved Ribbon Reels from scrapping that worth a 100k, and changed the process of material delivering to operation that stopped the root cause of Ribbon nonconformity.Elminiated MRB modules due to EL misjudgment.Corrected pre-El criteria that has been a reason of increasing MRB and eliminated rotating rework modules.Prevented diode mishandling and damage by establishing the ESD process and training on ESD tools and practices.invested in quality and production team talent and helped lifting them up to a leadership position to improve the process performance.collected a 500 improvement idea, one idea per each employee to be a great source of process improvement.3/21 to 5/23 lead Quality Engineer/ Electronic Boards-PCBA and power Microinverter.SALCOMP- CHENNAI/CHINA/USA-Mansfield texasLead the quality scope NPI and of transferring Salcomp Microinverter Manufacturing from India and China to global market in USA:-prepared the RDT Process qualification and validation plan for four Models PV Microinverter based on Customer PCBA Map and MechMap-lead team of quality engineers to prepare the qualification documentation reports that focuses on comparison of process parameters optimization of three CM locations access the US and India.-lead Build trail run and risk build yield and CAPA.- prepared the IPQC and IQC inspection work instructions.- participated in the ISO Audit.-Lead the training Of quality inspectors of 60 team members on the IPQC on the process PCB laser marking and solder paste printing. SMT pick and place, AOI inspection. Reflow and wave solder for through hole solder fill and X-Ray.Lead height test and IC testing and functional testing. Assembly of heat stalking and perimeter glue and bulk head on Carousel. Potting stage and hi-pot and gang test.11/2019 TO 3/2021 Principal Quality engineerSENNECA Dielectric Insulated heated Units for Cooling Systems.MY Role at Seneca is to participate in establishing a whole QMS process quality system from scratch to the whole plant from part, subassembly and assembly testing and shipping. Eliminate gaps and wastes.-led investigations and put technical solutions that saved 700k$ a year for one main defect. Also initiated a design change of the electric circuit that was approved by customers and saved at least 100k$ per work order and used the available raw material in house. Standardized all processes. Established IGU science training academy.Heat transfer design validation according to DOE and thermal software for convective and conductive unit.Prototypes and design validation, cooling loads and equipment.Operations Quality Control of electrical Resistance related to parts and assembly of the final product:A: 1-verification of the electrical Resistance of the received raw material.2- Verification of the Bus bar and soldering Material.3-validation of the heat treatment process related to the electrical resistance of the parts.B-Final Product Electrical [Hi-Pot, dielectric} testing and repairs.Engineering changes control due to Material availability and product electrical thermal requirements to customer max. Limits.Supplier Quality Control: First Article Inspection [FAI], FAI Engineering Verification, SCARs and Supplier corrective actions, Material verification and measurements, Material Review Board [MRB] control.Customer Complaints Control: CAPA.Process Control: Process verification and validation IQ, OQ, PQ, Quality Control Plan, process Capability.PPAP new Product.Quality Process improvement: Quality Visual Aids, Quality Alerts, standard work instructions.Skills Investment:Trained junior Engineers on electrical testing, process IQ, OQ, PQ.Trained QC, Team Leaders and Supervisors on Continuous Improvement and problem-solving tools.Generated third level of process leadership [group leaders].Connected the three departments in a one production process [part, sub-assembly-final product].Countermeasures:Redesign of process cut sheet that eliminated production process failure.Validation Plan and Method Statement to the Manufacturing process Modification start to end.Established the process of CSR input-engineering Release-production that eliminated production failure of building the right product per customer requirements.Saved a continuous work order for 100,000$ by modifying the electric circuit component with the available Raw Material.Created Master Document: Plant Product Process Matrix.PLC modification to include the inspection Cameras that saved a 1M$ waste Material only.Established Process Verification Process.Created master Validation plan, validation plan tasks and scheduling [IQ-OQ-PQ]Established a training unit and insulated glass processing classes insulated glass academy.Arranged and led a kaizen event.07/2017 10/2019 Sr.Quality Engineer IAC- AUTOMOTIVE Mansfield TXEstablished quality assurance protocols including process start-up and first piece approval and process check that eliminated all types of waste at early stage, that's for three shifts plant. We were able to save 200k$ of waste processed products.Leading the process validation part of the plant for plastic injection and thermoforming for new products.Leading the PPAP preparation and submission to GM. participated in preparing the QMS of the plant including the internal protocols.Trained production floor on Plastic injection defects by preparing scientific injection molding classes based on my training with Paulson scientific injection molding.02/2016 07/2017 Scapa Healthcare Knoxville. TNSr.Quality Engineer-Transfer ValidationResponsible for moving and process validation and production start-up for wound care remedy and clean room production lines from Scapa plant in Texas, California and Bayer in Cleveland TN to Scapa new plant in Knoxville TN.Manufacturing production lines such as: Lamination and slitter converting, Delta and Caulder presses, Freeze away and skin tag, Wrappers and printers.Leading team of supervisors and subcontractors to assign the projects tasks and follow up the schedule progress.Travel to all plants around the United States to conduct meetings to arrange for moving activities and train people on the process.1.Prepared plant layout.2.Prepared moving schedule and cost estimates.3.Prepared mechanical and electrical disconnection and reconnection plans.4.Prepared risk analysis.5.Prepared standard operation instruction for the assembly, labeling and packaging sections.6.Leading electrical and mechanical subcontractors to do the disconnection and reconnection process.7.Prepared Process Validation procedures and executed the IQ, OQ, PQ validation processes and conducted the qualification process to the production startup.02/2014- 02/2016 Quality Engineer - AISIN Automotive Knoxville, TNGravitational and Pressure die casting of Auto Engine Parts, CNC Machining and subassembly.-Review the lab CMM measurement and for TCC and VVT and CT SCAN for piston head.-Communicate measurement non-conformities with the process team and run root cause and process capability study.-Perform Poka yoke for pneumatic testing on machines after the failure of the part on the Quality testing.-Studied the root causes of the gap caused by flowing on non-tested parts between machining and subassembly.-Modified the Quality work instructions to stop flowing non tested parts to the customer.-Dismounting and analyze the customer returns and present the non-conforming features and business criticality.10/2012- 02/2014 Denso Automotive Manufacturing North America: Knoxville, TNProcess Engineer -Injection Molding & ELECTRONIC BOARDS ASSEMBLY AND TESTINGImproved the performance of three production lines by modifying the PLC sequence and die temperature sensors.Inspected the hydraulic press machine that presses the pump pulley to the bearing shaft, calculated the press fit, found out that the hydraulic pump is working on a pressure more than the maximum pressure!Modified the quality gates instructions to stop flowing bad parts to the customer.Connected the manufacturing team to the quality control team to fill the gap that causes bad parts05/2003 10/2012 DSD Manufacturing Solar and Gas power Plants Cairo.Sr. Mechanical Engineer project ManagerManufacturing for Renewable wind, Solar and Gas power plants.Led the Mechanical Engineering Department for Steel Fabrication Plant, providing technical Support and Preparing Fabrication drawing. Also led the engineering technical support for site erection of the boiler scope of steam power plants and hydro testing and equipment selection.Responsible for a work package of steel manufacturing projectsStudying the shop drawings to reach the optimum utilization of the material.Assign the required manufacturing processes and tools.Machine design for new product introduction NPIStrategic planning for new design tools for potential new projects.Design for manufacturing, tools modifications or design for new tools.Manufacturing planning, Task activities scheduling, manpower loading.Welding procedure specifications WPSWelding test and inspection.Projects I participated as a project manager /fabrication and constructionGAMESA Wind Towers Egypt Fabrication and construction of :117 Tower of V47-45m. 66MW (2Sections)100 Tower of G52-44m. 85MW (2 Sections)96 Tower of G52-55m. 80MW (3 Section142 Tower of G52-55m.120MW (3 Section)142 Tower of G52-55m.120MW (3 Section)Fabrication and construction of non-pressure parts (steel, piping, drum, air and gas ducts, insulation )1-Three units of HRSG GAS FIRED COMBINED Power Plant 1500MW /Egypt2-Four units Grain HRSG GAS FIRED COMBINED Power Plant 1250MW/UK3-Four units Staythopre HRSG GAS FIRED COMBINED Power Plant 1650MW/UKFabrication and construction for two units of gas/oil fired boilers non-pressure parts (steel, piping, drum, air and gas ducts, insulation )1- SHUAIBAH Steam Power Plant (Saudi Arabia): three units 300W, 36,000ton2-EL Tibbin Thermal Power Plant (Egypt): two units of gas/oil fired boilers 350MW/13,000ton3-Abu Qir Thermal Power Plant (Egypt) two units of gas/oil fired boilers 6500MW/24,000ton1-New Doha International Airport (Qatar): Fabrication and construction for 22,000 Tons Steel Structure for the Cargo Terminal of New Doha International Airport.2-Cairo North Power Plant Manufacturing and Erection of 2 HRSGs including all Critical Piping, Drums, Supporting Structure, Casing, Ducts and stacks. Turbine Casing3-Cairo West Power Plant Manufacturing and Erection of 6,000 Tons of Steel Structure for Turbine Building4-Sharm elshiakh international congress center, fabrication and construction /2000 ton steel structure05/2002 05/2003 FUTEC - Automotive Cairo, EgyptMechanical project EngineerLed plant transfer planning for disassembly of mechanical and electrical assemblies. Manufacturing of two additional production lines to increase capacity. Also lead transfer design improvements by designing mechanical and electromechanical systems to improve the efficiency of the Manufacturing Process.Prepared plant layout: die molding, risen, painting production linesPrepared material survey and detailed dies fabrication drawings, follow-up machining and fabrication at the workshop.Procurement material required for fabrication of two production lines.Procurement of compressor unit (screw compressor, reservoir, dryer, and steel pipes)Prepared material list for the factory, pneumatic lines (valves, cylinders, hoses, etc.)Supervision of the compressed air unit and pneumatic lines, fabrication and installation.Prepared material list for the factory hydraulic (hydraulic pump, cylinders, valves, and pipes)Procurement of all materials required for the factory hydraulic unit.Supervision of the installation of the factory hydraulic unit.Design calculation of air vacuum line of the grinding unitProcurement of the air vacuum line material (blower, hood, ducts, flexibles, supports)Supervision of fabrication and installation of the grinding units suction line.Prepared detailed drawings of the painting production line instead of manual painting units.05/2000 05/2002 POWER Automotive HVAC Cairo-EgyptMechanical Design Engineer design of evaporator and condenser and preparing 3D modeling and fabrication drawings.Design and 3D modeling of plastic parts of different HVAC products.Design and 3D modeling of Molds for plastic Parts.Preparing Fabrication drawings and BOM for Plastic parts and assemblies.Preparing Fabrication Drawings for Molds parts and assembly.Design and 3D modeling of sheet metal parts and assembly.Preparing fabrication drawings for sheet metal parts and assembly. |
