Osama Kamel

Experienced Control Section Head and Senior Control Engineer with over 16 years of expertise in managing and maintaining automated systems and machinery. Skilled in PLC programming, machine modifications, and HMI adjustments to improve system efficiency and minimize downtime. Proven leadership in overseeing maintenance teams, optimizing processes, and troubleshooting complex issues across industries including ceramics manufacturing and research centers.

Strong track record of restoring and enhancing equipment performance, demonstrated by the successful overhaul of automated lines and robots.

Control Section Head at Cyril for Ceramic and Porcelain (2023-06 – Present)

The department has 7 automated conveying lines (3 loading ceramic to boxes, 2 unloading and 2 kiln exits). The department also has 2 AGV robots that move ceramic boxes between machines.

• Managing of instrumentation department in daily activities.
• Managing strategic spare parts according to consumption.
• Schedule routing maintenance activities according to plant and manpower availability.
• Access HMI (Machine Humane Interface) to modify and update machine parameters.
• Generate daily reports for maintenance activities including routine and troubleshooting.
• Modifying automated conveying lines and AGV robots PLC program if there is problems that affects production process.

Control Section Head at Forsan for Ceramic and Porcelain (2024-10 – 2024-11)

The department has 14 automated conveying lines (8 loading ceramic to boxes, 3 unloading and 3 kiln exits). The department also has 3 AGV (Automated Guided Vehicle) robots that move ceramic boxes between machines.

• Managing of instrumentation department in daily activities.
• Managing strategic spare parts according to consumption.
• Schedule routing maintenance activities according to plant and manpower availability.
• Overhauling of 7 automated conveying lines, after 3 years of stoppage and make them work again with efficiency of 80%
• Fix problems between machines and the control room by modifying PLC.
• Modify machine by adding photocells on machine and add them on PLC program to protect the kiln.
• Access HMI (Machine Humane Interface) to modify and update machine parameters.
• Modify the PLC program for 4 machines to improve operability.

Control Shift Head at Ceramica Cleopatra Group, Galleria Factory (2022-02 – 2023-06)

The department has 53 automated conveying lines (18 loading ceramic to boxes, 11 unloading, 11 kiln exits, 13 automated conveying lines that move ceramic outside of production line). The department also has 12 AGV robots that move ceramic boxes between machines.

• Leading a team of instrument engineering in different daily tasks.
• Schedule routing maintenance activities according to plant and manpower availability
• Access HMI (Machine Humane Interface) to modify and update machine parameters.
• Generate daily reports for maintenance activities including routine and troubleshooting.

Senior Control Engineer at Ceramica Cleopatra Group, Fancy Factory (2020-01 – 2022-02)

The department has 35 automated conveying lines that includes (10 loading ceramic to boxes, 6 unloading, 6 kiln exits, 13 automated conveying lines (6 loading and 7 unloading) that moves ceramic outside of production line). The department also has 10 AGV robots that move ceramic boxes between machines.

• Check of conveyer's motors and gearboxes (Junction boxes, Gearbox backlash, noises, etc).
• Check for photocells, sensors, and cables.
• Maintenance of Encoder Sensors.
• Maintenance of limit switches.
• Troubleshooting of different problems like: VFD problems, contactors, and PLC.
• Checking, troubleshooting network problems that involve all automated conveying lines and AGV robots like fixing cables damage, replacement and resetting of access points, fixing continuity problems between automated conveying lines and AGV robots and control room.
• Maintenance and replacement of AGV's positive and negative magnet reader cards.

Senior Control Engineer at Makin Center for Research (2019-08 – 2020-01)

• Checking and maintaining laboratory instruments like centrifuges, lab shakers.

Senior Control Engineer at Xerox for Copying Machines (2018-02 – 2019-08)

Responsible for maintenance of Xerox in Suez-Zafarana District.

• Troubleshooting different failures of Xerox copying machines (Tuner Cartridges, Drum Cartridge, Fuser Assembly, …etc.).

Senior Control Engineer at Ceramica Cleopatra Group (2008-11 – 2018-02)

The department has 14 AGV forklift robots that move ceramic pallets outside the production area.

• Check periodically and maintain or replace parts that are damaged (mechanical or electrical parts).
• Check and maintain the hydraulic system for AGV forks.
• Check and maintain AGV motors, gearbox, liquid batteries, limit switches... etc.
• Resetting and reconfigure encoder sensors.
• Checking, troubleshooting network problems that involve all packaging lines and AGV robots like fixing cables damage, replacement and resetting of access points, fixing continuity problems between packaging lines and AGV robots and control room.

B. Sc. in Electrical Engineering (Specialization: Computer and Control Engineering) – Suez Canal University - Faculty of Engineering- Port Said (2003 – 2008)