Summary
Overview
Work History
Education
Skills
Accomplishments
References
Hobbies and Interests
CORE COMPETENCIES
Languages
PERSONAL INTERESTS
References
Timeline
Generic
KHAIRUL NIZAM AHMAD AMALI

KHAIRUL NIZAM AHMAD AMALI

Chemor

Summary

Results-oriented Maintenance Leader with 17+ years of progressive experience in mechanical maintenance, planning, and asset management across cement, manufacturing, and heavy industries. Proven expertise in preventive and predictive maintenance, RCM, budget management, and team leadership. Adept at using CMMS (MAXIMO) and driving large-scale shutdowns and cost-reduction initiatives. Committed to safety, continuous improvement, and equipment reliability.

Overview

18
18
years of professional experience

Work History

Planning Manager

Tasek Corporation Berhad
01.2023 - Current
  • Led preventive maintenance planning across the entire plant, including development of detailed job checklists, job lists, failure analysis processes, and scheduling of weekly and monthly maintenance tasks to ensure equipment reliability and minimize downtime.
  • Implemented Reliability Centered Maintenance (RCM) strategies for TCB plant, aligning maintenance activities with risk and performance priorities to improve operational efficiency.
  • Reviewed and controlled R&M expenses, driving cost optimization strategies and conducting weekly review meetings with top management to ensure alignment with the annual RM40M Repair & Maintenance budget.
  • Planned and tracked annual CAPEX for TCB, ensuring effective allocation of resources and prioritization of investment based on asset lifecycle and operational needs.
  • Maintained and improved the Computerized Maintenance Management System (CMMS) for accurate planning, work order tracking, and historical analysis; contributed to system upgrade projects to enhance planning capabilities.
  • Achieved >90% completion rate for preventive maintenance (PM) schedules, by refining planning processes and improving coordination with maintenance and production teams.
  • Managed the replenishment planning of critical spare parts, reducing stockouts and optimizing inventory levels for cost and availability.
  • Supervised 34 mechanical contractor personnel, handling daily planning, work allocation, and performance monitoring to align with plant priorities.
  • Initiated and led the HT Motor Harmonization Program, reducing spare part variety and improving planning efficiency for maintenance and procurement

Senior Maintenance Planner

Tasek Corporation Berhad
08.2018 - 01.2023
  • Managed plant-wide maintenance scheduling using MAXIMO.
  • Developed downtime reports, CBM strategies, and improvement initiatives.
  • Liaised with maintenance teams and production to ensure KPI fulfillment.

Maintenance Planner

Rema Tiptop Malaysia (Vale Project)
08.2017 - 08.2018
  • Attended client planning meetings (Vale) to align on job scopes, schedules, and shutdown activities, ensuring all maintenance tasks were coordinated and clearly defined before execution.
  • Developed and maintained detailed project files and maintenance schedules for each shutdown, providing clear timelines, job sequences, and task dependencies.
  • Liaised directly with the client throughout shutdowns, providing status updates, adjusting plans as needed, and ensuring all work was progressing according to schedule.
  • Coordinated manpower, tools, and equipment for both planned and unplanned (breakdown) shutdowns, ensuring proper allocation of resources across all job fronts.
  • Managed consumables and material usage at Manjung Plant, including planning, procurement coordination, and availability checks prior to job execution. Prepared and organized job fronts, ensuring that all required materials, tools, and documentation were available before work began to minimize delays.
  • Monitored the status of Maintenance Orders (MOs) raised by the client, tracked Field Service Reports, and ensured timely completion of all required documentation.
  • Prepared post-mortem reports for every completed shutdown, identifying successes, issues, and areas for improvement to enhance future maintenance planning. Reported to the Technical Manager and Contract Manager, delivering progress updates, challenges, and recommendations related to maintenance execution and planning.
  • Supervised a team consisting of 24 Belt Technicians, 2 Supervisors, 2 Work Preparators, and 1 Site Administrator, managing their activities and ensuring alignment with daily and shutdown maintenance plans.

Maintenance Planner

Tasek Corporation Berhad
04.2015 - 08.2017
  • Developed and implemented comprehensive Preventive Maintenance (PM) programs for plant equipment, including checklists, job plans, failure analysis, maintenance schedules, and equipment history records.
  • Performed Critical Parts Analysis (CPA) to ensure availability of essential spares and minimize equipment downtime.
  • Conducted detailed Downtime Analysis using tools such as Pareto and cause-by charts to identify trends and recommend corrective actions.
  • Utilized Condition-Based Monitoring (CBM) techniques including thermography, vibration analysis, and Non-Destructive Testing (NDT) to assess equipment health and predict failures.
  • Administered and optimized the use of the IBM MAXIMO Computerized Maintenance Management System (CMMS) for work order planning, scheduling, and execution.
  • Monitored and tracked work order progress to ensure timely completion and compliance with maintenance schedules.
  • Generated and presented weekly and monthly maintenance performance reports using data extracted from MAXIMO.
  • Provided first-line support and troubleshooting for MAXIMO system issues to ensure continuous operational effectiveness.
  • Planned, coordinated, and monitored all maintenance activities during major plant shutdowns (e.g., Chinese New Year & Kiln outages) to ensure safe and efficient execution.
  • Reported directly to the Division Maintenance Manager, supporting strategic planning and continuous improvement initiatives.

Executive Maintenance Engineer

UAC Berhad
08.2013 - 04.2015
  • Led the implementation of preventive maintenance (PM) programs for industrial vehicles and machinery, including forklifts, skid loaders, Tennant machines, and end loaders, using structured checklists, job lists, failure analysis, and maintenance history tracking to reduce breakdowns and extend equipment lifespan.
  • Performed critical parts analysis to identify high-risk components in vehicle systems, enhancing spare parts planning and reducing unplanned downtime. Conducted comprehensive downtime analysis (e.g., cause-by charts) across Garage, Facilities, and CBM areas to identify recurring failure trends and implement corrective actions.
  • Managed and coordinated Condition-Based Maintenance (CBM) programs, including vibration analysis and oil analysis, and developed monthly reports with actionable insights to optimize equipment reliability.
  • Oversaw daily operations of the Garage Department, ensuring timely maintenance and servicing of all site vehicles and mobile equipment.
  • Supervised carpentry and sieve-making operations, including pattern mold arrangement, suction box preparation, and sieve repair — contributing to smooth production support functions.
  • Directed facility maintenance activities for site infrastructure, including restrooms, roofing, roadways, and buildings, ensuring structural integrity and compliance with safety standards. Reported directly to the Maintenance Manager, providing detailed performance reports, maintenance schedules, and improvement plans.
  • Successfully championed a noise-reduction project in the autoclave area, winning a company-wide Safety Competition, and improving compliance with occupational safety standards.
  • Led a cross-functional maintenance team of 15 technicians, 2 supervisors, and 1 superintendent, overseeing work execution, scheduling, technical troubleshooting, and job quality assurance.

Maintenance Engineer

MAPA Gloves Sdn Bhd
11.2011 - 08.2013
  • Implemented a structured Preventive Maintenance (PM) program covering all critical plant equipment, including the development and use of checklists, job lists, failure analysis, and maintenance history records to improve asset reliability and reduce downtime.
  • Conducted critical part analysis for essential machinery to identify high-risk components and ensure timely replacement and availability, minimizing unexpected equipment failures.
  • Performed downtime analysis for major plant breakdowns using tools such as cause-by charts, enabling root cause identification and long-term corrective actions. Led improvement projects, including the installation of a side bar at Line 12, which resulted in a downtime reduction from 12% to 6%, significantly improving line efficiency.
  • Managed Condition-Based Maintenance (CBM) activities, including data collection, analysis, and reporting on key predictive techniques.
  • Possess working knowledge of advanced maintenance diagnostics such as vibration analysis, alignment, endoscopic inspections, NDT, DPT, oil analysis, and thermography, contributing to accurate equipment condition assessment.
  • Oversaw spare part availability and inventory history tracking, ensuring wear-and-tear components were always in stock to support continuous operations. Reported directly to the Maintenance Manager, delivering performance updates, CBM findings, and planning recommendations for continuous improvement.
  • Supervised a team of 12 shift technicians, 2 boiler men, 2 superintendents, and 1 clerk, ensuring effective daily operations, shift handovers, and maintenance execution in line with safety and quality standards.

Mechanical Engineer

Perak Hanjoong Simen (YTL Cement)
01.2008 - 11.2011
  • Served as Head of Mechanical Maintenance for the Packing Plant, leading the mechanical team and overseeing the execution of all weekly and monthly planned maintenance activities.
  • Developed and managed maintenance schedules for critical equipment, including inspections of bucket elevator elongation, belt hardness, table liners, and other high-wear components to ensure continuous plant reliability.
  • Led inspection and maintenance programs for locomotives and wagons, including scheduled servicing and condition assessments to ensure compliance with operational and safety standards.
  • Conducted regular wear and tear inspections and reporting for PHS (Product Handling System), ensuring data-driven maintenance interventions.
  • Responsible for the full scope of PHS maintenance activities, including Planned Maintenance, Scheduled Maintenance, Opportunity Maintenance, and daily routine inspections with comprehensive documentation and compilation.
  • Applied Reliability Centered Maintenance (RCM) and conducted Root Cause Analysis (RCA) for recurring mechanical issues, driving long-term improvements in system performance and equipment reliability.
  • Utilized advanced diagnostic tools and techniques, including vibration analysis, endoscopy, NDT (thickness testing), and oil analysis, to evaluate equipment health and predict failures.
  • Managed and coordinated a team of 4 technicians and 1 clerk, ensuring proper job delegation, performance monitoring, and adherence to safety and quality standards.

Education

Bachelor of Engineering - Industrial

Universiti Teknologi Malaysia (UTM)
JOHOR
04.2008

Skills

  • IBM Maximo (CMMS) and Microsoft Excel (Advanced)
  • PowerPoint proficiency
  • Diagnostic tools: Vibration, thermography, NDT, oil analysis
  • Preventive maintenance
  • Reliability centered maintenance
  • Computerized maintenance management
  • Downtime analysis
  • Budget management
  • Data analysis
  • Cross-functional collaboration
  • Budget preparation
  • Work Planning and Prioritization

Accomplishments

  • Saved RM9.7M in R&M costs (2021-2022) by optimizing vendor strategy and manpower
  • Cut scaffolding costs by 48% (RM2.1M to RM1.1M) via audit and control improvements
  • Developed an R&M cost monitoring file using Excel for budgeting efficiency
  • Led a safety initiative that won the company-wide Safety Innovation Award
  • Achieved over 90% completion rate for preventive maintenance (PM) schedules by refining planning processes and improving coordination with maintenance and production teams

References

Available upon request

Hobbies and Interests

  • Strategic online gaming enhances critical thinking, real-time decision-making, and strategic planning under pressure
  • Futsal promotes teamwork, communication, agility, and leadership in high-paced environments
  • Jogging demonstrates personal discipline, goal setting, and commitment to physical and mental well-being
  • Gunpla (Gundam model kit building) – develops attention to detail, patience, creativity, and precision through model assembly and customization

CORE COMPETENCIES

  • Preventive and predictive maintenance (PM, CBM, RCM)
  • Budget and cost control (OPEX and CAPEX)
  • CMMS Administration (IBM MAXIMO)
  • Team leadership and contractor management
  • Downtime & Root Cause Analysis (RCA, 5 Whys)
  • Critical Spare Parts Strategy & Inventory Optimization
  • Major Shutdown / Turnaround Planning
  • Reliability Improvement Initiatives
  • Safety Compliance & Audit Readiness

Languages

English
Proficient (C2)
C2
Malay
Native
Native

PERSONAL INTERESTS

  • Strategic online gaming enhances critical thinking, real-time decision-making, and strategic planning under pressure
  • Futsal promotes teamwork, communication, agility, and leadership in high-paced environments
  • Jogging demonstrates personal discipline, goal setting, and commitment to physical and mental well-being
  • Gunpla (Gundam model kit building) – develops attention to detail, patience, creativity, and precision through model assembly and customization

References

References available upon request.

Timeline

Planning Manager

Tasek Corporation Berhad
01.2023 - Current

Senior Maintenance Planner

Tasek Corporation Berhad
08.2018 - 01.2023

Maintenance Planner

Rema Tiptop Malaysia (Vale Project)
08.2017 - 08.2018

Maintenance Planner

Tasek Corporation Berhad
04.2015 - 08.2017

Executive Maintenance Engineer

UAC Berhad
08.2013 - 04.2015

Maintenance Engineer

MAPA Gloves Sdn Bhd
11.2011 - 08.2013

Mechanical Engineer

Perak Hanjoong Simen (YTL Cement)
01.2008 - 11.2011

Bachelor of Engineering - Industrial

Universiti Teknologi Malaysia (UTM)

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KHAIRUL NIZAM AHMAD AMALI