Ossama Badr
Australia
Summary
Results – driven Maintenance Reliability and Asset Integrity professional with 23 years of experience driving operational excellence across mining and diverse industries. Proven track record in developing and implementing maintenance strategies, optimizing asset lifecycle management, and applying risk-based inspection techniques to enhance equipment reliability and extend lifespan. Highly skilled in leveraging data-driven decision-making and analytical insights to drive continuous improvement. Adept at leading cross-functional teams to achieve measurable gains in safety, quality, and cost effectiveness while promoting sustainable operational performance.
Overview
23
23
years of professional experience
13
13
Certification
Work History
Senior Mechanical Reliability Eng.
Newmont (Newcrest Mining) Co., Lihir Gold Processing Plant
01.2023 - Current
- Provide technical leadership and address maintenance reliability issues, ensuring statutory compliance and optimal asset performance
- Successfully optimized maintenance strategies with FMEA and RCM, boosting equipment availability by 29% and reducing lifecycle costs across critical assets
- Spearheaded asset integrity initiatives, cutting equipment downtime by 15% and saving USD$5M annually in maintenance labour cost, and enhancing safety compliance
- Boosted OEE of lime slaking plant and cyanide plant by 15%
- Lead RCA and defect/Loss Elimination Action Platform LEAP, improving MTBF of critical equipment by 25%
- Develop and manage mechanical work packs for equipment repairs, including inspection testing plan ITPs and QA/QC checks, while providing technical support and oversight during plant turnaround and shutdowns
- Optimizing inventory levels of critical spares and saved $1.5M in material costs
- Developed and maintained asset condition risk register, published updates fortnightly to streamline maintenance planning and prioritize tasks effectively
- Reviewed condition monitoring reports and equipment watchlist, prioritized corrective actions, and created SAP maintenance work orders
- Developed 10Y maintenance reliability plan with scoping, procedures, BOMs, and maintenance task lists
- Delivered technical workshops and on-the-job training, boosting team proficiency in field maintenance and asset integrity practices
- Engaged actively in Reliability Steering Committee, Plant Audits, Newmont Full Potential Business Improvement
Reliability and Asset Integrity Lead
Tronox Global Co.
WA, AUS & KSA
12.2017 - 01.2023
- Company Overview: WA- Australia & KSA
- Led a multidisciplinary team of 17 engineers and inspectors, to support plant operations, driving asset integrity and reliability programs, and foster a continuous improvement culture
- Successfully implemented RCM program, optimized maintenance strategies (PM, PdM, CBM, RTF, TPM), and developed comprehensive maintenance procedures and work instructions, leading to $2.5M annual savings spare parts, a 25% reduction in PM costs, and a 20% improvement in PM compliance (2017-2019)
- Championed RCA investigations and defect elimination using FMEA/FMECA tool analysis; led risk assessments for equipment performance issues and implemented countermeasures to mitigate risks
- Developed and managed asset performance program for equipment and piping; developed Corrosion Integrity Management (CIM) systems, philosophies, and procedures and implemented Risk Based Inspection RBI pilot program (API 571, 580/581) in 2015-2017; employed asset risk register for tracking risks and keeping track interim repairs and replacements; oversaw Fitness-for-Service assessments (API 579-1 /ASME FFS-1) for safety and statutory compliance following API and ASME standards
- Reviewed and upgraded the plant wide valves structural specification (2016)
- Oversaw OPEX budget for reliability and inspection activities
- Managed maintenance and reliability CAPEX budget, developed yearly and 5-year asset management business plans for capital projects, and successfully executed a $72 million investment in 2019-2022, including business case, feasibility studies, option analysis, life cycle cost analysis, spending and risk mitigation plans
- Developed and managed equipment life extension program (2019-2022), eliminating 80% of equipment bad actors and achieved 85.6% On-Stream Time (OST), including
- Collaborated with OEMs and suppliers to enhance equipment design and optimize MRO critical spares, achieved $17M in savings (2018-2019) through efficient spares management and obsolete inventory reduction
- Provided engineering technical support for day-to-day maintenance operations, including QA/QC/Inspection and repairs of pressure vessels (API 510 & 572), storage tanks (API 575 & 653), piping systems (API 570 & 574), hands-on experience in execution of shutdowns, control of Management of Change (MOC), and more
- Acted as the Subject Matter Expert (SME) for metallurgical studies/ upgradation, corrosion and materials, refractory engineering systems (API 936, 975), FEA/stress analysis, mechanical design, asset improvement, addressing welding challenges, painting/coating systems, lining, insulation, and NDT inspection methods (i.e
- MPI, profile RT, PAUT, IRIS, Eddy current, RFT, MFL, LRUT)
- Actively engaged in Site Functional Deep Dive-OEE meetings and CAPEX Site committee, process safety plant auditing, and supported Tronox Global's Center of Excellence (CoE) Reliability to establish RAM targets and implement improvement projects
- Reported maintenance and reliability status (OEE, KPIs, risk register, condition monitoring) on weekly, monthly and quarterly
- Conducted technical training, safety briefings, and team coaching to boost safety and competency
- WA- Australia & KSA
Postdoctoral Researcher
Deakin University, Engineering School- IFM
Waurn Ponds, Australia
12.2014 - 09.2015
- Company Overview: Waurn Ponds 3217, VIC, AUS
- Conducted advanced research and development on manufacturing techniques, material modelling and stress analysis, focusing on optimizing forming processes and structural products for industrial applications
- Developed and validated predictive computational models and FEA simulation for high-strength titanium alloys and advanced high-strength steels (AHSS), significantly improving the manufacturing processes and product quality, in academic collaboration with POSTECH University- South Korea
- Delivered lectures and technical guidance to undergraduate and postgraduate engineering students, supervising their projects, master’s degrees and fostering academic excellence
- Teaching courses included: Mechanical design using Advanced AutoCAD and SolidWorks CAD, Manufacturing Engineering, Material Testings (Metallography, Destructive DT and Non-Destructive Testing NDT), Engineering modelling (FEA, Design, Analysis)
- Waurn Ponds 3217, VIC, AUS
Senior Manufacturing Eng. R&D
Australian Rollforming Co.
Dandenong, Australia
02.2011 - 11.2014
- Company Overview: Dandenong, VIC, AUS
- Applied computational modelling (FEA) to predict the performance of manufacturing processes and improve tool design for advanced high strength steels AHSS and titanium products
- Developed industrial guidelines for tool design and structural roll formed components, significantly reducing production defects
- Successfully optimized roll-forming processes, achieving improved product quality and reducing springback, boosting customer satisfaction
- Conducted material testing and mechanical analysis to ensure compliance with quality standards for manufactured products
- Delivered cost-effective and innovative solutions to address production challenges and improve overall efficiency
- Dandenong, VIC, AUS
Senior Manufacturing Eng. R&D
Kandil Steel Industries Co.
10th of Ramadan City, Egypt
11.2008 - 09.2010
- Company Overview: 10th of Ramadan City, Egypt
- Developed and optimized equipment capabilities in pickling, cold rolling, annealing, and hot-dip galvanizing, ensuring adherence to Life Cycle Asset Management LCAM principles
- Contributed to the design, installation, and commissioning of the second continuous galvanizing line, including key equipment such as rolling mills, annealing furnaces, and hot-dip galvanizing units, as well as established the process conditions
- Conducted asset health reviews and key analysis of equipment operational capabilities, identified improvement opportunities and value-added maintenance strategies/tasks and keep asset life cycle plans up to date
- Led feasibility studies, cost optimization, and technical analysis to enhance process conditions and equipment performance, achieving a 10% reduction in manufacturing cost
- Conducted trade-off evaluations of process alternatives, analysed findings to optimize decision-making, and developed control models, achieving a 6% market share increase for deep drawing and electrical steel products
- 10th of Ramadan City, Egypt
Senior Mechanical Reliability Eng.
Kandil Steel Industries Co.
10th of Ramadan City, Egypt
09.2005 - 10.2008
- Company Overview: 10th of Ramadan City, Egypt
- Conducted RCA for ad-hoc equipment issues and instigate the preventive measures to enhance asset reliability (i.e
- Rolling and skin pass mills, batch and continuous annealing furnaces, continues galvanize and painting lines, and slitting units)
- Oversaw monitoring of mechanical equipment using techniques such as vibration analysis, thermography, ultrasound, and oil analysis
- Optimized predictive and preventive maintenance programs to minimize downtime and reduce maintenance costs
- Led inspections activities an established risk registers for critical equipment and components
- Analysed equipment performance data to detect early signs of wear, fatigue or failure and ensuring timely maintenance and reduced downtime, as well as drive improvements for long-term reliability
- Provided technical guidance, training to reliability and maintenance teams and supervision to enhance operational efficiency
- Managed and updated critical spares inventory, ensuring accuracy and availability to support equipment reliability and operational continuity
- Prepared detailed reports and recommendations based on performance and monitoring data, supporting data-driven decision-making
- 10th of Ramadan City, Egypt
Asset integrity and QC Inspection Eng.
Kandil Steel Industries Co.
10th of Ramadan City, Egypt
06.2002 - 08.2005
- Company Overview: 10th of Ramadan City, Egypt
- Oversaw the repair and overhaul of equipment and piping, including welding (WPS, WPQR), NDT inspections, insulations, inspection of insulations and linings, determining repair/replacement scopes, generating mechanical work packs and reports and maintaining historical records
- Conducted in-process and final inspections for coating activities, covering material QC, ITPS, surface preparation, WFT/DFT checks, adhesion testing and holiday spark test
- Coordinated with third parties and contractors to review engineering designs, approve shop/fabrication drawings, and ensure compliance with company policies and technical standards through QC/QA processes
- Developed inspection and maintenance QA/QC checks as per OEM manuals and applicable standards
- 10th of Ramadan City, Egypt
Education
B.Sc. - Metallurgy & Materials Engineering
Suez University
EgyptM.Sc. - Manufacturing Engineering And Asset Improvement
Suez University
EgyptPh.D. - Mechanical Engineering
Deakin University
Waurn Ponds, VIC 3217, AustraliaSkills
- Reliability Engineering & Continuous Improvement
- Failure Modes & Effect Analysis (FEMA)
- Reliability-Cantered Maintenance (RCM)
- Maintenance Strategies Development & Optimization
- Condition Monitoring & Inspection
- Equipment Overhaul, Repair & QA/QC
- Life Cycle Cost Analysis (LCCA)
- Integrity Management for Pressure Vessels, Tanks & Piping
- Fitness for Service Evaluation
- Incident Investigation & Root Cause Analysis (RCA)
- Risk Management
- Metallurgy, Materials & Corrosion
- Capital Project Management
- Computational Modelling & Finite Element Analysis (FEA) & Stress Analysis
- Compliance with Industrial Standards & Regulations
- Safety-Driven
- Technical Leadership & Work Management
- Communication & Collaboration
- Data Analysis & Reporting
Certification
- CPEng NER APEC Engineer IntPE(Aus)- Professional Mechanical Engineer and Asset Management – Engineers Australia EA# 4773772.
- IEPNG-Professional Registered Engineer REG.ENG# 6100
- Certified Maintenance and Reliability professional, CMRP# 245501
- Advanced Reliability Analysis
- Apollo RCA & RCM, FMEA facilitator
- Corrosion and materials API 571
- Risk based inspection API 580
- Certified Materials Professional of Materials Australia, CMatP# 00926028.
- Quality management and Internal Audit, ISO9001-2015
- Statistical Analysis Control SAC
Affiliations
- Engineers Australia EA ID 4773772 MIEAUST- Mechanical Engineer and Asset Management
- Society of Maintenance and Reliability Professional SMRP# 573553
- American Society of Mechanical Engineer ASME# 103761707
- Association for Materials Protections and Performance AMPP# 867572
- Materials Australia Professional ID#00926028
- Institution of Engineers Papua New Guinea #12201
- Peer reviewer for international journals of Materials and design, and manufacturing processes.
Relevant Training
- Plant Performance Measurement System (PPMS)
- Asset management system ISO 55001
- Lubrication and Tribology
- Vibration analysis
- Motion amplification
- Lean Six Sigma
- CWI & NDTs inspection, ASNT level-II as per SNT-TC-1A
- API codes (API 510, API 570, API 653, API936)
Professional Qualities
- Strong analytical and problem-solving skills
- Attention to detail
- Integrity and safety-oriented
- Adaptability and resilient
- Results driven change leader
- Leadership and team collaboration
- Broad-minded and quick learner
Timeline
Senior Mechanical Reliability Eng.
Newmont (Newcrest Mining) Co., Lihir Gold Processing Plant
01.2023 - Current
Reliability and Asset Integrity Lead
Tronox Global Co.
12.2017 - 01.2023
Postdoctoral Researcher
Deakin University, Engineering School- IFM
12.2014 - 09.2015
Senior Manufacturing Eng. R&D
Australian Rollforming Co.
02.2011 - 11.2014
Senior Manufacturing Eng. R&D
Kandil Steel Industries Co.
11.2008 - 09.2010
Senior Mechanical Reliability Eng.
Kandil Steel Industries Co.
09.2005 - 10.2008
Asset integrity and QC Inspection Eng.
Kandil Steel Industries Co.
06.2002 - 08.2005
B.Sc. - Metallurgy & Materials Engineering
Suez University
M.Sc. - Manufacturing Engineering And Asset Improvement
Suez University
Ph.D. - Mechanical Engineering
Deakin University