Saghir Ahmed
Manassas Park
Summary
Results-driven Maintenance Manager with a strong background in reliability engineering and maintenance management in chemical and heavy industries. Expertise in executing maintenance strategies that optimize asset performance and minimize downtime, backed by a proven history of leading cross-functional teams and implementing continuous improvement initiatives.
Overview
17
17
years of professional experience
1
1
Certification
Work History
Maintenance Manager
Catalent Pharma Solutions
Manassas
01.2025 - Current
- Managed routine and preventive maintenance activities to optimize plant performance and ensure regulatory compliance.
- Planned, organized, and coordinated the use of all maintenance activities and resources within the facility.
- Managed maintenance department effectively to ensure smooth operations and team coordination.
- Identified and mitigated reliability risks, utilizing methodologies such as Root Cause Analysis (RCA), Reliability Centered Maintenance (RCM), and Predictive/Preventive Maintenance strategies.
- Advised the General Manager in matters related to equipment maintenance and impact of maintenance effort on equipment availability.
- Communicated equipment needs and necessary repairs to production team, allowing timely adjustments to production schedules.
- Delivered technical support to the maintenance department for routine issues and oversaw mechanical/electrical contracts.
- Collaborated with the Safety Department to ensure compliance with safety protocols and participate in Process Hazard Analysis (PHAs).
Maintenance Manager
SICPA Securink Corporation
Springfield
09.2023 - 11.2024
- Developed and maintained the plant's asset management system, ensuring accurate and up-to-date documentation of equipment, maintenance history, and spare parts inventory.
- Executed root cause analyses and implemented corrective actions for equipment failures and process inefficiencies.
- Coordinated with manufacturing team to minimize downtime and enhance plant performance.
- Trained and mentored maintenance and production staff, promoting continuous improvement and teamwork.
- Managed team planning and staff development, executing staff succession and growth plans for a department of 7 employees.
- Led projects in process development and construction, adhering to established policies and safety practices.
- Engaged with other North American Hub resources to leverage expertise and create synergies across operating units.
Site Maintenance/Reliability Leader
Dupont ArmorWall
Salisbury
10.2021 - 09.2023
- Developed and coordinated annual maintenance work schedule, optimizing contractor services and rentals to ensure efficient completion of maintenance tasks.
- Coordinated maintenance activities with operations, inspection, and process group, managing maintenance contractors and overseeing hiring processes to align with operational goals.
- Worked on asset criticality for the site, reviewing maintenance plans based on criticality analysis.
- Analyzed non-conformance and KPI data for trends, developed reports for management, and recommended continuous improvement projects to enhance processes.
- Completed maintenance activity reports and documentation, providing accurate records to support operational transparency and compliance.
- Oversaw succession planning and team development initiatives for 30 employees.
- Supported the site expansion team and provided recommendations to the engineering team for new asset design and construction.
- Ensured employees adhered to safe work practices and performed work efficiently.
Sr. Engineer Mechanical Reliability/ Maintenance (HSM)
ArcelorMittal/Nippon Steel Corp.
Calvert
12.2017 - 09.2021
- Conducted criticality analysis for assigned area, distributing assets based on risk priority number and developing maintenance plans aligned with asset classification.
- Executed MTAs for bad actors in the area, authored SMP and PM for the assigned area.
- Executed delay analysis to identify bad actors impacting reliability in the area.
- Worked as an Asset Reliability/EMP Engineer, extracting and analyzing data for A3/RFCA, QK, 5 Why’s, etc.
- Led a team of 12 members, including Associate Reliability Engineers, Inspectors, Planners, Schedulers, Millwrights, and Reliability Technicians.
- Supported area maintenance manager on weekends by managing maintenance tasks and coordinating team efforts to ensure efficient operations.
- Ensured a safe working environment was maintained.
Plant Maintenance/Reliability Specialist IV (Wastewater and Finishing Area)
Great Lakes Works, US Steel Corp
Ecorse
05.2014 - 11.2017
- Coordinated maintenance work with departments to improve equipment efficiency and support production goals.
- Worked on criticality analysis for the assigned area, distributing assets based on Risk Priority Number and creating maintenance plans based on asset classification.
- Conducted root cause investigations and implemented corrective actions to prevent recurrence of issues.
- Updated equipment data, PMs, task lists, and diagnostic methods to improve reliability.
- Followed up on PdM findings with area maintenance planners for predictive and preventive maintenance programs.
- Interfaced with procurement to ensure that all supplies, parts, and materials were available when required.
- Supported in the development and implementation of operating and capital improvement budgets; oversees procurement process. Participates with the Superintendent and General Manager with the annual budget process.
- Assisted with treatment system upgrades and with the development of related plans.
- Developed and maintained standard operating procedures, training staff on SOPs to ensure compliance and operational consistency.
Senior Engineer Reliability/Performance for Rail cars/Steam Plant area
WMATA
Washington
09.2012 - 05.2014
- Developed and implemented analytical methodologies for reviewing reliability, performance, and warranty data in MAXIMO for HVAC and Door sub-systems in railcars, leading to informed recommendations and monitoring of sub-system campaigns' progress.
- Managed responsibilities associated with steam generation plants and chillers to ensure efficient performance.
- Evaluated equipment failure trends and repair history, identifying gaps in equipment life expectancy to inform maintenance strategies.
- Assisted task forces to enhance reliability and maintainability practices, contributing to improved operational standards.
- Analyzed ELES (Elevators/Escalators) system performance, preparing reports to identify weak links.
- Provided information to the Warranty Management Specialist to execute warranty management programs for vehicle and component contract procurements.
Reliability Engineer
Hemlock Semiconductor Corp.
Hemlock
06.2009 - 08.2012
- Led mechanical integrity and predictive maintenance inspection activities to ensure safe, reliable, and efficient manufacturing processes with minimal downtime.
- Tracked MTBR, MCBF, OEE, and TEEP, enhancing reliability of plant equipment operations.
- Assessed equipment health through thermography, oil analysis, and implemented necessary corrective actions.
- Evaluated and resolved equipment efficiency issues, authored SOPs and SMPs to standardize operations.
- Supported maintenance and reliability engineering within a high-hazard and high-purity chemical manufacturing and plant operations team.
- Procured critical spares, facilitating uninterrupted plant operations.
- Led Lean manufacturing programs and project portfolios, identifying new opportunities, training personnel on Lean principles, and driving projects to completion.
Education
Master of Science (M.S.) - Industrial Engineering
New Jersey Institute of Technology
Newark, NJBachelor of Science (B.S.) - Mechanical Engineering
N.E.D. University of Engineering & Technology
Sindh, PakistanSkills
- Predictive maintenance
- Condition Based Maintenance
- Root Cause Analysis
- Maintenance planning
- Asset Management
- Continuous Process Improvement
- Equipment Capacity Analysis
- MSHA training
- Budget management
- Project Management
- MS Project
- MAXIMO
- SAP
- PI System
- Minitab 16
- MS-Office
- C Programming
- Visual Basic
- Asset Tracking
- Contractor management
- Project coordination
- Facilities management
- Equipment inspection
- Performance evaluation
- Cost Benefit Analysis
- Sustainability Practices
- Team leadership
- Sustainability Practices
- Situational Leadership
- Problem-solving abilities
- Facility Layout
- OSHA
- MSHA training
- Facilities management
Certification
- Six Sigma Black Belt
- Six Sigma Green Belt
- Six Sigma Lean Manufacturing
- PMP trained
Selected Assignments And Projects
- Calvert, AL, Worked on CAPEX assignments to improve uptime for the Coiler area such as Side Guide coupling modification, addition of saddles in front of Coilers to minimize damage to the assets due to un-balanced coil, modification of coil bander frame for safe and efficient exchange of coil cars.
- Ecorse, MI, Worked as Reliability/Maintenance Engineer for the following, CGL Welder, W tubes for Radiant Tubes Furnace, Entry Looper Issues and Grids for the Cleaning Section.
- Hemlock, MI, Worked as Reliability Engineer for the following Vertical Hybrid Harvest, Base plate Cleaning units, lifting tool for compressor packing, Refurbishment of piston rod and crosshead for D-R compressors, High/Intermediate pressure packing trial for process compressor and rebuild of Origa rails for Cleaning units.
Websites
Timeline
Maintenance Manager
Catalent Pharma Solutions
01.2025 - Current
Maintenance Manager
SICPA Securink Corporation
09.2023 - 11.2024
Site Maintenance/Reliability Leader
Dupont ArmorWall
10.2021 - 09.2023
Sr. Engineer Mechanical Reliability/ Maintenance (HSM)
ArcelorMittal/Nippon Steel Corp.
12.2017 - 09.2021
Plant Maintenance/Reliability Specialist IV (Wastewater and Finishing Area)
Great Lakes Works, US Steel Corp
05.2014 - 11.2017
Senior Engineer Reliability/Performance for Rail cars/Steam Plant area
WMATA
09.2012 - 05.2014
Reliability Engineer
Hemlock Semiconductor Corp.
06.2009 - 08.2012
Master of Science (M.S.) - Industrial Engineering
New Jersey Institute of Technology
Bachelor of Science (B.S.) - Mechanical Engineering
N.E.D. University of Engineering & Technology