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Work Background and Activities

Karam Sheikh Khaled
Karam Sheikh Khaled

Karam Sheikh Khaled was the manager of the Dubai office of Saudi Cast, an industrial company that produces castings and sanitary fittings. As manager, his responsibilities included: 1. Managing three main projects - product development and improvement, website development, and obtaining third-party certification. This involved meeting with clients to understand their needs and feedback. 2. Developing a comprehensive work plan for product development using tools like a communication plan, work breakdown structure, and project network diagram. He applied a stage-gate development process and division development into scoping, solution development, testing, and launch. 3. Overseeing the design, manufacturing, testing, and documentation of new and improved products to

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KARAM SHEIKH KHALED Design and Development Engineer Work Background and Professional Activities 1) Managing technical work in Dubai Office a) Introduction. 1. This work experience was taking place from January 2014 till February 2015. I was working as a manager of Saudi Cast office in Dubai (the central Engineering and Designing office of FloDrain products in gulf area). "Saudi Cast" is an industrial company for castings and sanitary fittings. It was established in 1972 as the first Iron and Steel foundry in Saudi Arabia. b) Background. 2. FloDrain is the trade name of the drainage products which include roof drains, floor drains, and cleanouts. Each product is a set of many metal parts; some of these parts are produced by Saudi Cast's facilities and other by different suppliers. 3. Depending on marketing researches, it was agreed that the company needs to get certified according to international standards, and to communicate with engineering consulting offices to sell FloDrain products around GCC's countries. 4. Top management decided to open new office in UAE for many purposes: Managing the development process of FloDrain products in a way that carries out the customers' requirements in GCC. Obtaining a third party certificate according to the related ASME standards. Getting approvals from consultants and designers; Including FloDrain name in the consultants' vendor lists as an approved product for any project. Designing and implementing a new website for FloDrain products with many tools that help both customers and marketing team. 5. As the required work in the office was more technical and requires engineering background, our management appointed me as the manager of the office in Dubai. 6. Before moving to the new office, I prepared a basic plan that describes the nature of the work and presents ideas for each main step of work. 7. Nature of work as specified in the basic plan: Meeting famous consultants and designers (construction projects) continuously to identify their needs. Products Development and improvement. Preparing complete data for each product and determining the important values that make the physical product valuable. Preparing for getting DCL (Dubai Central Laboratory) certificate. Developing new website for FloDrain products. c) Personal activity. 8. At the beginning and before moving to Dubai, I analyzed the major goals and initiatives taken by the company's top management in order to enter new markets around GCC, and specified the
objectives in details to start preparing a basic plan that identifies my ideas and suggestions about the required work flow and the sequence of basic activities. 9. There were three main projects: Products development and continuous improvement. Website Development. Third party certificate. Each project requires a good communication with the clients (consultants, contractors and designers) to get clear and accurate information about the new products opportunities, the required certificates and documents to get approvals, and the required data about installation and functionality. 10. Below I describe the main activities I made in "Meeting the clients" step: i. I started our work by visiting the clients to present our products. Our marketing team was arranging for the visits, and I was going with them to the major consultants and designers. ii. A report of the presentation will be prepared including the clients' feedback and the discussions that had been carried out during the visits. I checked every report and analyzed the clients' requirements. Also, I had to specify and prioritize the opportunities of new developments and improvements. iii. After three months, I stopped this task and arranged for a meeting to discuss the results and to finalize in details all the targets of our work. iv. I reported to top management the clients' needs, the expected volume of products development, different recognized parties that can provide compliance certificate according to ASME standards, and the qualification process to add FloDrain name in consultants and designers' vendor list. "Products development and continuous improvement" project 11. I prepared a comprehensive work plan which basically includes: i. The communication and reporting plan: This was so important because the development process is performed in Dubai while the manufacturing in Saudi Arabia. I specified the information to be communicated including the format and the content of the reports, the level of details, the methods and technologies that may be used to convey the information, the frequency of the communication, and the status review meetings. ii. Work Breakdown Structure (WBS) and Project Network Diagram (PND): As the required developments were specified, I prepared with my design team WBS and then assigned the required resources and duration for each activity to build the schedule. I used Microsoft Project to release Gantt chart, Resources histogram, and PND. After I completed preparing PND, I distributed the project schedule and resources schedule to the design team and the production department in Saudi Arabia. iii. I had prepared the change control system which organized proposing, reviewing and allowing changes within the project. Every team member was able to propose - by formal template - any change in any activity. I was responsible to approve the requested change by reviewing each change as per its value, cost, impact, and feasibility. Also, changes were entered, tracked and recorded in either approval or denial. 12. I had applied the stage-gate development process to meet clients' requirements; the opportunity was specified clearly from the customer, and the business case study was performed during "Meeting the clients" step. I had divided the development process into four stages; Scoping, development of the solution, Test and validate, and Launch. All the responsibilities were assigned in the project plan.
i. Scoping stage involved analyzing client's needs in terms of the application which the product has to fit with, the functionality of the product, necessary features, and the common sizes of the product and drainage pipes for the required application. I had specified the quality metrics of each product type of the three families; Roof drains, Floor Drains, and Cleanouts, as per ASME standards. These metrics were used in the 3rd stage "Test and Validate". ii. Development of the solution: I had prepared a complete process for developing the solution; I applied in that process the latest techniques and tools in designing and developing the products. Development stage goes through many steps: A. 3D initial designing (part and Assembly using Solidworks). B. Checking and approving: As I have good experience in production processes of sand casting, I have to check each initial design in terms of the manufacturability, and the compliance with standards. As I had built strong relations during "Meeting the clients" step with senior engineers in MEP department in many consulting offices, I'm taking the advantages to share our developments with them; I send the new designs to get the feedback about the product's features and functionality. C. Sending details-drawing of the final product to the suppliers. D. Design for Manufacturing (DFM) of the parts which will be produced in our facilities: Adding manufacturing allowances, selecting the parting line (Methoding), and designing gating and risering system. Each development can cover more than one part, each part has DFM. Once the design engineer completes his assigned responsibilities, I have to check the DFM documents for the next step. E. When the DFM is approved, the design team will start preparing "Product's Documents". I had explained in the plan what are the product's documents and how they can be prepared, and I prepared a template of each one. Products' documents are including installation drawing, installing instruction, product data sheet, product drawing (for customer), rendered images, Revit file, and AutoCAD file. I applied the latest techniques to produce rendered images of different materials and appearances for each product. Product's documents will be finalized and released after passing the 3rd stage "Test and Validate". F. When I approve DFM, I have to request for producing three trial castings of the developed product; the products will be produced in Saudi Arabia and passed through many sequential processes; pattern (mold) making, sand molding, pouring, finishing, and assembling. I have to track these processes which are performed in Saudi Arabia to stay on schedule. G. As I suggested to top management in the basic plan that we need to start finding the product's engineering values such as the flow rate of storm drains (Roof drains and Area drains), I tried to find the best way that makes these values useful and trusted to the consultants and designers. I arranged with IAPMO R&T LAB based in US (International Association for Plumping and Mechanical Officials) to determine the rain flow rate through Saudi Cast's roof drains by applying the tests as per section 7.2 Recommended test protocol to be added to ASME A112.6.4 of Storm Drainage System Research Project Flow rate through Roof Drains by ASPE (American Society of Plumping Engineers). The values were determined for different outlet sizes, different piping arrangements (Straight and Offset), and different head of water (layer of rain water on the roof). These results are used in designing the roof drainage system.
iii. Test and Validate: When the developed product is ready, it will be sent to quality assurance lab to perform the required tests as per the work plan. A test report will be sent to me to evaluate it and analyze the development process. If the results are perfect, I will ask the design team to send products' documents to me for checking. iv. I have to track suppliers' performance by sending the received parts to quality assurance lab to perform the required tests as per the specified metrics (chemical composition, mechanical properties, dimensions, features, and finishing). From the tests results and the delivery time, I am evaluating the supplier's performance. "Website development" project 13. In the basic plan, I suggested to top management building a powerful website with central data base. It will also include useful tools for sales team and for clients. 14. I had planned to build a central database for all FloDrain products including the new developed and the existing products. The database contains products' documents with explanation of the area of application and engineering specifications of each product. For that, I had ordered to prepare the products' documents for the existing products in the same templates and quality of the new developed products. 15. I managed developing new tools that encourage the clients to use our products easily and to get clear and accurate information. As we determined the flow rate values of our roof drains, I developed a new tool by the name "Design Calculator" to help MEP engineers in the design of the drainage system when using our products. Calculations are performed by applying the "Rational Method Formula" documented in Plumbing Engineering Design Handbook Volume 2 by ASPE, using climate data (Rainfall rates) issued by the meteorological centers and flow rates for each of our products, taking into account the roof surface, roof loading, and piping arrangement. Also, I managed developing a new tool by the name "Product Selection" which helps the client in finding the proper product for specific application. 16. On the other hand, I have developed a special tool that can be used by our sales team; this tool was called "Submittal Builder". It can build submittals automatically by entering the specification which came from the construction project designer; it helps sales team to prepare the submittals in very short time and in a uniform style. Also it helps the management to track sales team performance as the created submittals are saved online and should be classified as per the consultant's remarks. A report of the sales performance is created every three months including the ratio of the approved projects to the submitted. 17. I had designed with the design and marketing teams the wireframe of the website and selected the website developers company to work with us on developing the new website. "Getting approved and third party certified" project 18. Third Party Certificate "DCL" (Dubai Central Laboratory): I applied to get the factory assessment certificate for our Saudi Cast in Saudi Arabia as roof drains and floor drains producer. Then, I arranged for the auditing visit in Riyadh, Saudi Arabia. I was responsible for any clarification regarding the product and its compliance with the ASME standards. d) Summary. 19. I tried in this work experience to move the product to higher level; the developments were meeting the clients' needs, and complying with the standards. I have managed developing about 50 new products; each product has different sizes and different material options. The website is so useful and helps all departments to get deep knowledge about the products. It helps also the
clients in their work. We have received many compliments about the website; http://flodrain.saudicast.com/ The company now is certified by DCL and approved by many consultants and designers. 2) Research and Development Projects a) Introduction. 1. This work experience was taking place from August 2012 till January 2014. I was working as development engineer in "Saudi Cast" at head office in Riyadh, Saudi Arabia. I was responsible for administrating some researches and developments that would benefit the company to expand the products range, produce new materials, decrease production cost, and improve products quality in general. b) Background. 2. In the last ten years, "Saudi Cast" started an improvement strategy which addressed production processes in particular. "Saudi Cast" started to invest in new production technologies such as: automatic high-pressure molding machines (match-plate type), CAD/CAM in patterns making. 3. In parallel, "Saudi Cast" started researches and developments to take extreme advantages from the applied technologies. I had started with preparing development system by applying the stage- gate process. I performed the discovery stage by suggesting a lot of ideas that can translate the vision of the top management for about one year. 4. After that, I had applied the first gate in the process to select the most promising ideas by sharing with the management all the ideas that came from first stage to get the approval of three developments. 5. The three developments which the management had selected were: Feeding System Design software for Ductile Iron castings. Austempered Ductile Iron (ADI). New designing simulated method for manhole covers. 6. As this type of projects was new to the company, the top management was observing the efficiency of our work and how the developments and researches could fit with the comprehensive development strategy. So, I had to prepare three plans in parallel with limited resources. I had selected my team to start the projects; the team was basically consisted of two C# programmers, three production engineers, two marketing specialists, and two design engineers. 7. The main objectives of "Feeding System Design software" project were: Developing computer software by the name of FEEDING SYSTEM DESIGN (FSD) for Ductile Iron castings in green sand and chemically bonded sand systems to calculate the optimal design of gating and risering system which provides high quality castings. Improving the casting yield by using the minimum riser size capable of feeding the casting properly. Creating a report of the study with details drawing; then, sending the report to pattern makers. 8. The main objectives of "Austempered Ductile Iron (ADI)" project were: Replacing the alloy steel by Austempered Ductile Iron (ADI) in high performance products such as: digger tooth, pavement breaker bodies and heads, and wear resistant parts. Developing a cost-effective method of implementing each step of producing ADI products with taking into account the ergonomics factors.
Combining all the steps in one production line which should fit with the main existing line. 9. The main objectives of "New designing simulated method" project were: Developing a completely new method of designing the manhole covers by using simulation software to make Stress-Strain analysis. Reducing products weight (reducing product price). Eliminating the wasted time and materials (reducing production cost). c) Personal activity. 10. I had started my work by building a suitable system for the new department; the system was built to fit company's capabilities in terms of human resources, company's experience in R&D, and some unavailable technologies. I had applied the Stage-Gate process to the system and let the development leads the researches. So, for each one of the three selected developments, we had one or more researches involved in each stage of development process. 11. After many meetings with top management, I finalized the system which would be followed. 12. I was responsible alone to perform the "Discovery Stage". I had identified a set of promising developments with basic study of each one. Then I had prepared for the 1st gate meeting with all departments' managers and top management to select the most promising ideas by using specified criteria in terms of the required time and the expected cost of each development, and how beneficial the deliverables would be. 13. I had specified the criteria of each gate in each project, and I managed a meeting for each gate to analyze and evaluate the previous stage. 14. For "Feeding System Design Software" project, I had divided the development process into four stages; Scoping and researching (Creating the algorithm), Software development (programming), Test and Validate, and Launch. i. Scoping and researching stage involved studying the solidification of Ductile Iron, determining the effect of cooling rate on the volume change during solidification, specifying risering methods, and then writing the algorithm. The research was prepared with reference to "ASM metals handbook volume 15, casting" and "Ductile Iron - the essentials of gating and risering system design - Rio Tinto Iron & Titanium Inc.". I had explained in the plan all the steps of the research which ended by releasing flow charts covering all the options that the user could make; these charts were the base of code writing. I had specified the quality metrics of each objective and how to measure them; the metrics were basically about the soundness of the casting (Free of porosity and shrinkage), casting yield, and the created report. These metrics were used in the 3rd stage "Test and Validate". ii. Software development stage: I was working in this stage with the programmers, I had to check each step of programming which included the interface look, the ease of use, the logical sequence as per the algorithm, the way of presenting the results, and the report template. iii. Test and Validate stage: After completing the programming stage, I had to check each calculated value manually to ensure that coding process was correct. I found out some problems which were fixed easily. Then, I started to test the software on real castings. I chose different existing castings which were produced in alloy steel or Ni-white iron and changed the gating and risering system by using the developed software to produce them in Ductile Iron. I asked QC lab to check the casting by applying ultrasonic test. The last step was to check the yield improvement, I chose different existing castings which were
produced in Ductile Iron, and redesign the gating and risering system by using the developed software. I had compared the yield between the old and new designs. iv. Launch stage: In this stage, I managed preparing a guideline for using this software and arranged to install the software on designers' computers. By the end of this stage, the project was completed. 15. For "Austempered Ductile Iron (ADI)" project, I had divided the development process into five stages; Scoping and researching of ADI, Business case, Treatment unit development, Test and Validate, and Launch of the unit for continuous production. i. Scoping and researching stage involved studying ASTM A 897 standards to specify the grades and their properties, comparing Austempered Ductile Iron with various competitive materials, and understanding the reason behind the great combination of ADI's properties. I had specified the quality metrics of each grade related to the chemical composition, the mechanical properties, and the microstructure. These metrics were used in the 4th stage "Test and Validate". Also, I had determined the production parameters (heat treatment variables) to meet ADI's grades. I prepared a research about the ADI market as well as the most famous clients within that market. ii. Business case stage: I had explained in the plan how to identify clients' needs and requirements by employing the dual processes of interacting with target clients while also making use of background research. I met - with the marketing specialists of my team - the most famous clients of this business in Saudi Arabia to discuss the opportunities of replacing alloy steel with Austempered Ductile Iron. Also I had built strong relationships with new clients to get a clear image about the market size and to provide a solution for their needs by selecting the grade of ADI. I tried to maintain communication with the clients by regular visiting or by email to get the feedback and suggestions during "Testing the results" stage. iii. Treatment unit development stage: Austempered ductile iron is produced by applying an isothermal heat treatment on conventional Ductile Iron castings. This stage involved creating a treatment unit. I asked my team to suggest a method of implementing each step of the treatment (Pre-heating, Austenizing, and Austempering). After that, I selected the best idea of each step and built a complete unit which provided smooth process cycle, effective cost, desired productivity, and ergonomic workplace. The unit consisted of one pre-heating furnace (Electrical resistance type), one Austenizing furnace (chloride based salt-bath immersed electrode), and two Austempering furnaces (Nitrate based salt-bath immersed electrode). I specified the required resources for the unit (Equipment, workers, treatment salts, and tools for the operations). Also, I had evaluated the cost addition of automating the treatment unit. I had contacted with many suppliers and received quotations about the cost of the furnaces. The top Management selected "WellMake Engineering Company Pvt.Ltd. India" to supply the furnaces. iv. Test and Validate stage: In the project plan, I explained how to test the development of the treatment unit; I started with treating tensile test specimens and then testing them to validate the quality metrics in terms of the chemical composition, microstructure, and the mechanical properties. Then, I performed the second step which was the producing real products and validate the performance in-application test. I had applied that on digger tooth. I collected the tests results and evaluated them, I noticed that the clients required more toughness with high wear resistance; So, I changed the grade to meet their requirements.
v. Launch stage: In this stage, I presented "on the job training (OJT)" for the workers who would be responsible for the new treatment unit. And by the end of this stage, the project was completed. 16. For "New designing simulated method" project, the development process was easier and simpler than the previous two projects. It was about applying a simulation-driven design on the manhole covers to simulate the loading test as per BS EN 124. For the project, I had suggested using Solidworks premium for performing the simple required simulation. At the university, I had studied materials behavior under stress and Finite Element Method (FEM) simulations, I prepared and presented training course for design engineers about the Finite Element Method (FEM) simulations which correctly predict the mechanical behavior of cast components, the training included basically the main differences in mechanical behavior between brittle and Ductile material, the suitable criteria for each behavior, the steps of simulation process in general, and analyzing the simulation results. During my education, I used ANSYS to perform a stress-strain analysis; therefore, using Solidworks was easy to me. I arranged for a training course of the new tools for all the designers. Below I describe the main steps I made in this project: i. I had selected different existing manhole covers which were complying with the BS EN 124 in loading test. ii. The design engineers in my team applied the simulation on the selected covers to reduce the weight as much as possible with providing enough factor of safety. Then, I checked all the designs before applying the changes on patterns. iii. I asked QC lab to test the changed castings. I collected all the actual results and compared them with simulation results. iv. I had planned for implementing solidworks in design department's computers. d) Summary. 17. There were big challenges in this work experience, I was performing research and development projects in a company which didnt have any R&D project before, the resources were limited, the three developments were completely new to my team members, and the management didn't hire any researcher as it was observing how the developments would start. During the developments, some problems and mistakes came out, and they were fixed immediately. The projects were completed on time. Our design center is using the feeding system design software, ADI material entered the target market and it is produced continuously, and the manhole covers are designed by using Stress-Strain simulation.

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Work Background and Activities

  • 1. KARAM SHEIKH KHALED Design and Development Engineer Work Background and Professional Activities 1) Managing technical work in Dubai Office a) Introduction. 1. This work experience was taking place from January 2014 till February 2015. I was working as a manager of Saudi Cast office in Dubai (the central Engineering and Designing office of FloDrain products in gulf area). "Saudi Cast" is an industrial company for castings and sanitary fittings. It was established in 1972 as the first Iron and Steel foundry in Saudi Arabia. b) Background. 2. FloDrain is the trade name of the drainage products which include roof drains, floor drains, and cleanouts. Each product is a set of many metal parts; some of these parts are produced by Saudi Cast's facilities and other by different suppliers. 3. Depending on marketing researches, it was agreed that the company needs to get certified according to international standards, and to communicate with engineering consulting offices to sell FloDrain products around GCC's countries. 4. Top management decided to open new office in UAE for many purposes: Managing the development process of FloDrain products in a way that carries out the customers' requirements in GCC. Obtaining a third party certificate according to the related ASME standards. Getting approvals from consultants and designers; Including FloDrain name in the consultants' vendor lists as an approved product for any project. Designing and implementing a new website for FloDrain products with many tools that help both customers and marketing team. 5. As the required work in the office was more technical and requires engineering background, our management appointed me as the manager of the office in Dubai. 6. Before moving to the new office, I prepared a basic plan that describes the nature of the work and presents ideas for each main step of work. 7. Nature of work as specified in the basic plan: Meeting famous consultants and designers (construction projects) continuously to identify their needs. Products Development and improvement. Preparing complete data for each product and determining the important values that make the physical product valuable. Preparing for getting DCL (Dubai Central Laboratory) certificate. Developing new website for FloDrain products. c) Personal activity. 8. At the beginning and before moving to Dubai, I analyzed the major goals and initiatives taken by the company's top management in order to enter new markets around GCC, and specified the
  • 2. objectives in details to start preparing a basic plan that identifies my ideas and suggestions about the required work flow and the sequence of basic activities. 9. There were three main projects: Products development and continuous improvement. Website Development. Third party certificate. Each project requires a good communication with the clients (consultants, contractors and designers) to get clear and accurate information about the new products opportunities, the required certificates and documents to get approvals, and the required data about installation and functionality. 10. Below I describe the main activities I made in "Meeting the clients" step: i. I started our work by visiting the clients to present our products. Our marketing team was arranging for the visits, and I was going with them to the major consultants and designers. ii. A report of the presentation will be prepared including the clients' feedback and the discussions that had been carried out during the visits. I checked every report and analyzed the clients' requirements. Also, I had to specify and prioritize the opportunities of new developments and improvements. iii. After three months, I stopped this task and arranged for a meeting to discuss the results and to finalize in details all the targets of our work. iv. I reported to top management the clients' needs, the expected volume of products development, different recognized parties that can provide compliance certificate according to ASME standards, and the qualification process to add FloDrain name in consultants and designers' vendor list. "Products development and continuous improvement" project 11. I prepared a comprehensive work plan which basically includes: i. The communication and reporting plan: This was so important because the development process is performed in Dubai while the manufacturing in Saudi Arabia. I specified the information to be communicated including the format and the content of the reports, the level of details, the methods and technologies that may be used to convey the information, the frequency of the communication, and the status review meetings. ii. Work Breakdown Structure (WBS) and Project Network Diagram (PND): As the required developments were specified, I prepared with my design team WBS and then assigned the required resources and duration for each activity to build the schedule. I used Microsoft Project to release Gantt chart, Resources histogram, and PND. After I completed preparing PND, I distributed the project schedule and resources schedule to the design team and the production department in Saudi Arabia. iii. I had prepared the change control system which organized proposing, reviewing and allowing changes within the project. Every team member was able to propose - by formal template - any change in any activity. I was responsible to approve the requested change by reviewing each change as per its value, cost, impact, and feasibility. Also, changes were entered, tracked and recorded in either approval or denial. 12. I had applied the stage-gate development process to meet clients' requirements; the opportunity was specified clearly from the customer, and the business case study was performed during "Meeting the clients" step. I had divided the development process into four stages; Scoping, development of the solution, Test and validate, and Launch. All the responsibilities were assigned in the project plan.
  • 3. i. Scoping stage involved analyzing client's needs in terms of the application which the product has to fit with, the functionality of the product, necessary features, and the common sizes of the product and drainage pipes for the required application. I had specified the quality metrics of each product type of the three families; Roof drains, Floor Drains, and Cleanouts, as per ASME standards. These metrics were used in the 3rd stage "Test and Validate". ii. Development of the solution: I had prepared a complete process for developing the solution; I applied in that process the latest techniques and tools in designing and developing the products. Development stage goes through many steps: A. 3D initial designing (part and Assembly using Solidworks). B. Checking and approving: As I have good experience in production processes of sand casting, I have to check each initial design in terms of the manufacturability, and the compliance with standards. As I had built strong relations during "Meeting the clients" step with senior engineers in MEP department in many consulting offices, I'm taking the advantages to share our developments with them; I send the new designs to get the feedback about the product's features and functionality. C. Sending details-drawing of the final product to the suppliers. D. Design for Manufacturing (DFM) of the parts which will be produced in our facilities: Adding manufacturing allowances, selecting the parting line (Methoding), and designing gating and risering system. Each development can cover more than one part, each part has DFM. Once the design engineer completes his assigned responsibilities, I have to check the DFM documents for the next step. E. When the DFM is approved, the design team will start preparing "Product's Documents". I had explained in the plan what are the product's documents and how they can be prepared, and I prepared a template of each one. Products' documents are including installation drawing, installing instruction, product data sheet, product drawing (for customer), rendered images, Revit file, and AutoCAD file. I applied the latest techniques to produce rendered images of different materials and appearances for each product. Product's documents will be finalized and released after passing the 3rd stage "Test and Validate". F. When I approve DFM, I have to request for producing three trial castings of the developed product; the products will be produced in Saudi Arabia and passed through many sequential processes; pattern (mold) making, sand molding, pouring, finishing, and assembling. I have to track these processes which are performed in Saudi Arabia to stay on schedule. G. As I suggested to top management in the basic plan that we need to start finding the product's engineering values such as the flow rate of storm drains (Roof drains and Area drains), I tried to find the best way that makes these values useful and trusted to the consultants and designers. I arranged with IAPMO R&T LAB based in US (International Association for Plumping and Mechanical Officials) to determine the rain flow rate through Saudi Cast's roof drains by applying the tests as per section 7.2 Recommended test protocol to be added to ASME A112.6.4 of Storm Drainage System Research Project Flow rate through Roof Drains by ASPE (American Society of Plumping Engineers). The values were determined for different outlet sizes, different piping arrangements (Straight and Offset), and different head of water (layer of rain water on the roof). These results are used in designing the roof drainage system.
  • 4. iii. Test and Validate: When the developed product is ready, it will be sent to quality assurance lab to perform the required tests as per the work plan. A test report will be sent to me to evaluate it and analyze the development process. If the results are perfect, I will ask the design team to send products' documents to me for checking. iv. I have to track suppliers' performance by sending the received parts to quality assurance lab to perform the required tests as per the specified metrics (chemical composition, mechanical properties, dimensions, features, and finishing). From the tests results and the delivery time, I am evaluating the supplier's performance. "Website development" project 13. In the basic plan, I suggested to top management building a powerful website with central data base. It will also include useful tools for sales team and for clients. 14. I had planned to build a central database for all FloDrain products including the new developed and the existing products. The database contains products' documents with explanation of the area of application and engineering specifications of each product. For that, I had ordered to prepare the products' documents for the existing products in the same templates and quality of the new developed products. 15. I managed developing new tools that encourage the clients to use our products easily and to get clear and accurate information. As we determined the flow rate values of our roof drains, I developed a new tool by the name "Design Calculator" to help MEP engineers in the design of the drainage system when using our products. Calculations are performed by applying the "Rational Method Formula" documented in Plumbing Engineering Design Handbook Volume 2 by ASPE, using climate data (Rainfall rates) issued by the meteorological centers and flow rates for each of our products, taking into account the roof surface, roof loading, and piping arrangement. Also, I managed developing a new tool by the name "Product Selection" which helps the client in finding the proper product for specific application. 16. On the other hand, I have developed a special tool that can be used by our sales team; this tool was called "Submittal Builder". It can build submittals automatically by entering the specification which came from the construction project designer; it helps sales team to prepare the submittals in very short time and in a uniform style. Also it helps the management to track sales team performance as the created submittals are saved online and should be classified as per the consultant's remarks. A report of the sales performance is created every three months including the ratio of the approved projects to the submitted. 17. I had designed with the design and marketing teams the wireframe of the website and selected the website developers company to work with us on developing the new website. "Getting approved and third party certified" project 18. Third Party Certificate "DCL" (Dubai Central Laboratory): I applied to get the factory assessment certificate for our Saudi Cast in Saudi Arabia as roof drains and floor drains producer. Then, I arranged for the auditing visit in Riyadh, Saudi Arabia. I was responsible for any clarification regarding the product and its compliance with the ASME standards. d) Summary. 19. I tried in this work experience to move the product to higher level; the developments were meeting the clients' needs, and complying with the standards. I have managed developing about 50 new products; each product has different sizes and different material options. The website is so useful and helps all departments to get deep knowledge about the products. It helps also the
  • 5. clients in their work. We have received many compliments about the website; http://flodrain.saudicast.com/ The company now is certified by DCL and approved by many consultants and designers. 2) Research and Development Projects a) Introduction. 1. This work experience was taking place from August 2012 till January 2014. I was working as development engineer in "Saudi Cast" at head office in Riyadh, Saudi Arabia. I was responsible for administrating some researches and developments that would benefit the company to expand the products range, produce new materials, decrease production cost, and improve products quality in general. b) Background. 2. In the last ten years, "Saudi Cast" started an improvement strategy which addressed production processes in particular. "Saudi Cast" started to invest in new production technologies such as: automatic high-pressure molding machines (match-plate type), CAD/CAM in patterns making. 3. In parallel, "Saudi Cast" started researches and developments to take extreme advantages from the applied technologies. I had started with preparing development system by applying the stage- gate process. I performed the discovery stage by suggesting a lot of ideas that can translate the vision of the top management for about one year. 4. After that, I had applied the first gate in the process to select the most promising ideas by sharing with the management all the ideas that came from first stage to get the approval of three developments. 5. The three developments which the management had selected were: Feeding System Design software for Ductile Iron castings. Austempered Ductile Iron (ADI). New designing simulated method for manhole covers. 6. As this type of projects was new to the company, the top management was observing the efficiency of our work and how the developments and researches could fit with the comprehensive development strategy. So, I had to prepare three plans in parallel with limited resources. I had selected my team to start the projects; the team was basically consisted of two C# programmers, three production engineers, two marketing specialists, and two design engineers. 7. The main objectives of "Feeding System Design software" project were: Developing computer software by the name of FEEDING SYSTEM DESIGN (FSD) for Ductile Iron castings in green sand and chemically bonded sand systems to calculate the optimal design of gating and risering system which provides high quality castings. Improving the casting yield by using the minimum riser size capable of feeding the casting properly. Creating a report of the study with details drawing; then, sending the report to pattern makers. 8. The main objectives of "Austempered Ductile Iron (ADI)" project were: Replacing the alloy steel by Austempered Ductile Iron (ADI) in high performance products such as: digger tooth, pavement breaker bodies and heads, and wear resistant parts. Developing a cost-effective method of implementing each step of producing ADI products with taking into account the ergonomics factors.
  • 6. Combining all the steps in one production line which should fit with the main existing line. 9. The main objectives of "New designing simulated method" project were: Developing a completely new method of designing the manhole covers by using simulation software to make Stress-Strain analysis. Reducing products weight (reducing product price). Eliminating the wasted time and materials (reducing production cost). c) Personal activity. 10. I had started my work by building a suitable system for the new department; the system was built to fit company's capabilities in terms of human resources, company's experience in R&D, and some unavailable technologies. I had applied the Stage-Gate process to the system and let the development leads the researches. So, for each one of the three selected developments, we had one or more researches involved in each stage of development process. 11. After many meetings with top management, I finalized the system which would be followed. 12. I was responsible alone to perform the "Discovery Stage". I had identified a set of promising developments with basic study of each one. Then I had prepared for the 1st gate meeting with all departments' managers and top management to select the most promising ideas by using specified criteria in terms of the required time and the expected cost of each development, and how beneficial the deliverables would be. 13. I had specified the criteria of each gate in each project, and I managed a meeting for each gate to analyze and evaluate the previous stage. 14. For "Feeding System Design Software" project, I had divided the development process into four stages; Scoping and researching (Creating the algorithm), Software development (programming), Test and Validate, and Launch. i. Scoping and researching stage involved studying the solidification of Ductile Iron, determining the effect of cooling rate on the volume change during solidification, specifying risering methods, and then writing the algorithm. The research was prepared with reference to "ASM metals handbook volume 15, casting" and "Ductile Iron - the essentials of gating and risering system design - Rio Tinto Iron & Titanium Inc.". I had explained in the plan all the steps of the research which ended by releasing flow charts covering all the options that the user could make; these charts were the base of code writing. I had specified the quality metrics of each objective and how to measure them; the metrics were basically about the soundness of the casting (Free of porosity and shrinkage), casting yield, and the created report. These metrics were used in the 3rd stage "Test and Validate". ii. Software development stage: I was working in this stage with the programmers, I had to check each step of programming which included the interface look, the ease of use, the logical sequence as per the algorithm, the way of presenting the results, and the report template. iii. Test and Validate stage: After completing the programming stage, I had to check each calculated value manually to ensure that coding process was correct. I found out some problems which were fixed easily. Then, I started to test the software on real castings. I chose different existing castings which were produced in alloy steel or Ni-white iron and changed the gating and risering system by using the developed software to produce them in Ductile Iron. I asked QC lab to check the casting by applying ultrasonic test. The last step was to check the yield improvement, I chose different existing castings which were
  • 7. produced in Ductile Iron, and redesign the gating and risering system by using the developed software. I had compared the yield between the old and new designs. iv. Launch stage: In this stage, I managed preparing a guideline for using this software and arranged to install the software on designers' computers. By the end of this stage, the project was completed. 15. For "Austempered Ductile Iron (ADI)" project, I had divided the development process into five stages; Scoping and researching of ADI, Business case, Treatment unit development, Test and Validate, and Launch of the unit for continuous production. i. Scoping and researching stage involved studying ASTM A 897 standards to specify the grades and their properties, comparing Austempered Ductile Iron with various competitive materials, and understanding the reason behind the great combination of ADI's properties. I had specified the quality metrics of each grade related to the chemical composition, the mechanical properties, and the microstructure. These metrics were used in the 4th stage "Test and Validate". Also, I had determined the production parameters (heat treatment variables) to meet ADI's grades. I prepared a research about the ADI market as well as the most famous clients within that market. ii. Business case stage: I had explained in the plan how to identify clients' needs and requirements by employing the dual processes of interacting with target clients while also making use of background research. I met - with the marketing specialists of my team - the most famous clients of this business in Saudi Arabia to discuss the opportunities of replacing alloy steel with Austempered Ductile Iron. Also I had built strong relationships with new clients to get a clear image about the market size and to provide a solution for their needs by selecting the grade of ADI. I tried to maintain communication with the clients by regular visiting or by email to get the feedback and suggestions during "Testing the results" stage. iii. Treatment unit development stage: Austempered ductile iron is produced by applying an isothermal heat treatment on conventional Ductile Iron castings. This stage involved creating a treatment unit. I asked my team to suggest a method of implementing each step of the treatment (Pre-heating, Austenizing, and Austempering). After that, I selected the best idea of each step and built a complete unit which provided smooth process cycle, effective cost, desired productivity, and ergonomic workplace. The unit consisted of one pre-heating furnace (Electrical resistance type), one Austenizing furnace (chloride based salt-bath immersed electrode), and two Austempering furnaces (Nitrate based salt-bath immersed electrode). I specified the required resources for the unit (Equipment, workers, treatment salts, and tools for the operations). Also, I had evaluated the cost addition of automating the treatment unit. I had contacted with many suppliers and received quotations about the cost of the furnaces. The top Management selected "WellMake Engineering Company Pvt.Ltd. India" to supply the furnaces. iv. Test and Validate stage: In the project plan, I explained how to test the development of the treatment unit; I started with treating tensile test specimens and then testing them to validate the quality metrics in terms of the chemical composition, microstructure, and the mechanical properties. Then, I performed the second step which was the producing real products and validate the performance in-application test. I had applied that on digger tooth. I collected the tests results and evaluated them, I noticed that the clients required more toughness with high wear resistance; So, I changed the grade to meet their requirements.
  • 8. v. Launch stage: In this stage, I presented "on the job training (OJT)" for the workers who would be responsible for the new treatment unit. And by the end of this stage, the project was completed. 16. For "New designing simulated method" project, the development process was easier and simpler than the previous two projects. It was about applying a simulation-driven design on the manhole covers to simulate the loading test as per BS EN 124. For the project, I had suggested using Solidworks premium for performing the simple required simulation. At the university, I had studied materials behavior under stress and Finite Element Method (FEM) simulations, I prepared and presented training course for design engineers about the Finite Element Method (FEM) simulations which correctly predict the mechanical behavior of cast components, the training included basically the main differences in mechanical behavior between brittle and Ductile material, the suitable criteria for each behavior, the steps of simulation process in general, and analyzing the simulation results. During my education, I used ANSYS to perform a stress-strain analysis; therefore, using Solidworks was easy to me. I arranged for a training course of the new tools for all the designers. Below I describe the main steps I made in this project: i. I had selected different existing manhole covers which were complying with the BS EN 124 in loading test. ii. The design engineers in my team applied the simulation on the selected covers to reduce the weight as much as possible with providing enough factor of safety. Then, I checked all the designs before applying the changes on patterns. iii. I asked QC lab to test the changed castings. I collected all the actual results and compared them with simulation results. iv. I had planned for implementing solidworks in design department's computers. d) Summary. 17. There were big challenges in this work experience, I was performing research and development projects in a company which didnt have any R&D project before, the resources were limited, the three developments were completely new to my team members, and the management didn't hire any researcher as it was observing how the developments would start. During the developments, some problems and mistakes came out, and they were fixed immediately. The projects were completed on time. Our design center is using the feeding system design software, ADI material entered the target market and it is produced continuously, and the manhole covers are designed by using Stress-Strain simulation.