Eng. Kamal Ashraf
Metal Doors Official & Industrial Production Engineer
Specialized in hollow metal fire-rated doors, sectional door automation, lean factory plant redesign, CNC fabrication, and data-driven material optimization. Proven track record in orchestrating multi-line operations and delivering high-spec mega projects in Saudi Arabia.
B.Sc. Mechanical Engineering (First Class Honors)
King Faisal University, Al-Hasa, KSA
Work Experience
Mechanical Production Engineer
Al-Barrak Automatic Garage Doors (Al-Hasa, KSA)
20 Key Projects & Accomplishments
1200 HMD Doors Project for Makkah
Directed the complete manufacturing and on-time delivery of 1,200 non-fire-rated Hollow Metal Doors for Makkah.
Sectional Door Line Relocation & Capacity Optimization
Relocated line to main factory, boosting daily output from 3 to 5 doors (+66%) and reducing bubble defects to 5%.
Factory Floor Plan & Layout Redesign
Re-engineered internal logistics pathways, equipment placement, and safety zones using AutoCAD, boosting efficiency by 45%.
Systematic Odoo & Real-Time Production Interface
Automated factory workflow from Odoo order intake to assembly and shipping dispatch with live Google Sheets tracking.
UL Fire-Rated Certification Activation
Activated global UL fire-rated standards compliance for Hollow Metal Door lines, enabling entry to enterprise mega-projects.
Coil Slitting & Scrap Reduction Mathematical Model
Developed mathematical slitting models for 50 cm and 60 cm panel profiles to minimize scrap rates and control COGS.
Machinery Revival & Automated Lines Re-commissioning
Recommissioned critical dormant machinery including CNC Plasma Cutters, Orbital Pipe Welders, and Shutter Foam Lines.
Scrap & Stagnant Inventory Repurposing Program
Reclaimed over 90% of steel scrap and stagnant inventory to fabricate lock bars, motor covers, and structural angles.
Frameless MOD Door Design & Architectural Integration
Engineered a frameless MOD door featuring concealed framing and hidden pivot mechanisms for seamless interior aesthetic.
Sliding & Swing Panoramic Door Systems
Designed ultra-slim profile sliding and swing panoramic doors with reinforced metallic frames for modern villas.
Custom Photocell Sensor Mounting Brackets
Designed custom mounting brackets for photocell safety sensors, ensuring optical alignment and faster site fitting.
Sectional Sliding Gate & Heavy-Duty Mortise Lock
Engineered heavy-duty sectional sliding gates and service doors with seamlessly integrated mortise locks.
Shutter Line Automation & Central Lock Synchronization
Mechanically and programmatically linked central lock punching with shearing machines to eliminate manual operations.
Industrial Powder Coating & Wood-Grain Texture Finishing
Introduced durable wood-grain texture coating, solved matte paint defects, and created manual paint blends.
HR Steel Sheet & 3D Plastic Motor Cover Realization
Designed heavy-duty HR steel motor covers and developed a 3D plastic injection concept cutting steps from 7 to 1.
Modified Industrial Drum & Shaft Tolerance Redesign
Re-engineered industrial cable drum dimensions and keyway tolerances to optimize torque transmission and lifespan.
Exhibition Booths & Custom Showroom Displays
Engineered and built structural exhibition booths for Saudi Building Exhibitions (Riyadh & Jeddah) and regional showrooms.
NEOM Project Technical Approvals & Submittals
Secured approved technical submittals and shop drawings for heavy-duty industrial rolling shutters at Sindalah Amenities, NEOM.
Loading & Logistics Area Layout Optimization
Redesigned factory loading bays, established systematic loading procedures, and trained dispatch crews.
Factory Safety & Environmental Compliance Overhaul
Established secure chemical storage zones, enforced safety uniform standards, and conducted fire safety training.
Coil Slitting & Scrap Reduction Simulator
Based on Eng. Kamal's mathematical slitting model for 50cm & 60cm panel profiles. Adjust master coil dimensions to calculate real-time sheet utilization and scrap reduction percentages.
Technical Core Competencies
CAD & Engineering Software
- AutoCAD (Advanced 2D/3D Drafting & Layouts)
- SolidWorks (Mechanical Part & Assembly Design)
- Creo Parametric (Detailed Modeling & Sheet Metal)
Manufacturing & Machinery
- CNC Plasma Cutting Machines
- Pipe & Orbital Welding Systems
- Polyurethane Foam Injection Lines
- Sheet Metal Bending & Hydraulic Presses
- Industrial Powder Coating & Sublimation
Production & Operations
- Lean Manufacturing & Kaizen
- Scrap & Waste Optimization
- Material Requirements Planning (MRP)
- Factory Plant Layout Redesign
- Odoo ERP System Integration
Quality & Safety Standards
- UL Fire-Rated Door Compliance (UL 10B/10C)
- ISO Quality Management Systems
- OSHA General Industry Safety Standards
- OHSAS Safety Protocols
Data Engineering & Management
- Advanced Microsoft Excel (Mathematical Models & Formulas)
- Live Production Status Tracking Dashboards
- Raw Material Slitting & Weight Calculators
- Technical Specifications & Method Statements
Certifications & Courses
Lean Manufacturing Training Course
SIDF Academy • 2024
General Industry Safety OSHA Compliance
ILTC • 2023
AutoCAD Comprehensive & Advanced Training
Udemy • 2023
Fundamentals of Engineering (FE) Mechanical
King Faisal University • 2022
SolidWorks Fundamentals
KFU / ASME Student Section • 2022
Learn Creo Parametric: Basic to Advanced
Udemy • 2021
OHSAS Industrial Safety Certifications
Professional Training Institute • 2022
Education
Bachelor of Science in Mechanical Engineering
First Class Honors (GPA: 4.77 / 5.00)
King Faisal University, Al-Hasa, KSA
Let's Build Engineering Excellence
Open for high-level industrial production engineering roles, project management, and specialized door manufacturing consultations in Saudi Arabia and the Gulf region.