Kabiru Rufai(Msc.Cssgb) Email & Phone Number

Ludwigshafen, De

• Support Operations team as required to ensure safe manufacturing, process troubleshooting, development of standard operating procedures (SOP's)• Supported capital project with equipment design,sizing,P&ID update and review, cost estimate for the project's development and justification analysis, construction and installation supervision, construction walk-downs, start-up, commissioning, and documentation• Troubleshoot and addressed process quality issues, NCMs and quality deviation• Tracked Production efficiency,downtime,cycle times, product yield, first- pass- quality and production volume• Practiced responsible care 14001 through active participation in responsible care management system• Supported and participated in site quality audit requirement and ISO9001 QMS.• Initiated MOC,PSSR for new and existing project that need modification and Perform plant walk-down to perform P&ID and PFD verification with As-Is condition in plant and create red line mark-up for the gaps.• Tracked and improved Unit KPIs,including volume and quality goals through optimization of existing system• Improved Filtration efficiency with cost saving of $0.5Millons• Supported new product development from pilot plant to production floor, supported Operators and laboratory with clear guidance on manufacturing instruction and sampling during production• Supported site EHS policy on plant weekly walkthrough, Live Permit Audits, and incident investigation

Spring, Texas, Us

Facilitated PSM related activities such as PHA for safety of plant integrity and emission monitoring, Management of change (MOC), and completion of corrective and preventive action (CAPA) and issue related to EPA and TCEQProvided guideline and strategies in reducing Offspec creation and minimizing creation of Offspec in the first place during production.Provided support to operations personnel to troubleshoot day-to-day operations of unit performance (reactors, dryers, mixers, Fluid bed cooler, fire heater etc.) and work closely with Operators on Pre-Startup Safety Reviews (PSSR) as well as during production to correct issues that affect operationPerformed plant operation optimization studies and monitored KPI monitoring existing assets performance and expectation.Performed process simulation to establish baselines, simulate modification and estimate performance enhancement to existing plant operations.Served as a SME/Technical Manager for scrubber/thermal oxidizer commission, reactors operation, assisted the operators with Sops, testing and documentation to ease their jobsSuccessfully optimized and Reduced cycle time in all reactors, tracked and improved yield, reduced operating cost, operational variability using statistical process control(SPC) as well as process capabilityPrepared operating procedures (SOP) as clear guidance for Operators to improve performance and efficiency of production process. Provided technical input for maintenance of raw materials usage (SAP bill of materials), corrected production data and work notification for maintenance departmentLead root cause analysis studies to resolve plant process and equipment related issuesLead continuous improvement using lean six sigma methodology with emphasis on cost Reduction, capacity improvement/cycle time reduction and waste reduction

Houston, Texas, Us

Lead performance efficiency of mud/spacer/ cement compatibility testing, made corrective action to necessary remediation Managed slurry batch recipes for all products by maintaining master product recipe Collaborated with product regulatory for the plant for any deviation and needed correction Work on improvements to existing processes to improve product and process quality by monitoring and conducting planned experimentation for critical to process parameters Utilize structured problem-solving methods to identify root causes and solutions for process problems deviation such as SPC, lean and six sigma Lead and carried out compressive testing, thickening time, rheology testing of cement slurry with 98% accuracy with modification when required to meet customer design requirement

Houston, Texas, Us

Assisted in development of new products and presided over product samples runs; managed all aspects of site Process Safety program and ensured compliance with OSHA Process Safety Management (PSM) and EPA Risk Management Program (RMP) regulations.•Developed, analyzed, and tracked experimental process capability. Draw conclusion with statistical analysis chart (SPC), Pareto chart, SIX SIGMA DAMIC, Kaizen with corrective action.•Supporting the development of new testing protocols to meet the needs of R&D program objective•Designed and modified ongoing processes to support new and existing technologies.•Worked with design engineer on effective design, scaled-up and transitioned new products to manufacturing (pilot and loadout bulk slurry products).•Develop process flow charts, work instructions, process sheets, checklists, forms, and other required documentation.•Operated, and monitored additives formulation reactions and conduct associated analytics research on surfactant / polymer performance on mud-spacer.

Tracked daily Unit refinery plant operations’ performance (e.g. production rate, quality of the refined and in-line process, product yield, chemical usage, operating cost, and energy utilization).•Lead and assisted during technical support for production troubleshooting, problem-solving, and root cause analysis of the process issues with opportunity for improvement, plant start up and shutdown•Supported turnaround/maintenance activities such as Lock out tag out, EIP development, dryers, vessel inspection•Supported, Identified, and lead process improvements to reduce cost, increase capacity, and extend capability (variability, cycle-time, complexity, and scrap reduction)•Monitored KPIs to drive process optimization and improvement with collaborated with production manager using analytical statistical tools such minitap.•Prepared PFD development with heat and material balance sheet, process datasheet, pump calculation, line pressure drop calculation, hydraulic analysis, relief load calculation, air cooler design, Process hazard analysis (Hazop, PSM)•Provided technical expertise related to equipment operations / repairs and during units’ turn around (includes vessel inspection, plant shut down / decontamination, EIP / confined space inspection development with details instruction, log-out and tag-out).•Assisted Operations in quality improvements, cost reduction, and equipment utilization through statistical analysis (SPC) and Six Sigma techniques, DMAIC, DOE etc.

Master Of Science, Chemical And Biomolecular Engineering

Master Of Science, Chemical Engineering, Chemical And Biomolecular Engineering

Chemical Enginering, Chemical And Process Engineering

High School Diploma, Science