MFC Maintenance Specialist Instrumentation
Samancor Chrome Ltd.
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Job summary
Samancor Chrome Ltd. is seeking a senior electrical/automation engineer to lead maintenance and RCA activities across instrumentation, control and automation. The role focuses on minimizing downtime, analysing failure history and implementing robust reliability improvements.
You will develop, maintain and monitor adherence to maintenance standards and specifications, work with Siemens PLCs/SCADA systems, and support plant readiness and continuous improvement initiatives.
Qualifications
- Degree or National Diploma in Electrical (Light Current), Electronic, Industrial Automation Engineering or equivalent
- External: 6 years’ relevant experience
- Internal: 4 years’ relevant CU experience
- Valid Driver’s License (minimum B/ Code 8)
Responsibilities
- Identify and mitigate risk exposures within area of responsibility.
- Analyse RCFA investigations and facilitate problem solving.
- Develop and maintain maintenance plans, SPUs and SOW data.
- React swiftly to plant stoppages involving instrumentation or automation faults.
- Backup instrumentation software programs and ensure availability.
- Monitor uptime data and apply corrective actions where necessary.
- Provide technical advice to team and customers; log engineering requests.
Skills
Education
Tools
Job description
To continuously improve the Asset Capability Assurance process in a safe manner, through Root Cause Failure Analysis on high frequency and high-cost breakdowns and analysing maintenance performance. Maintain all measurement, automation and control related equipment to ensure minimal production downtime and maximize production while utilizing automation technology to improve safety and efficiency.
To continuously improve the Asset Capability Assurance process in a safe manner, through Root Cause Failure Analysis on high frequency and high-cost breakdowns and analysing maintenance performance. Maintain all measurement, automation and control related equipment to ensure minimal production downtime and maximize production while utilizing automation technology to improve safety and efficiency.
- Identify and assess level of issue-based risk exposures in area of responsibility by considering exposures to business, financial, legal issues, people, equipment, material, environment, processes, etc.
- Consider the level of risk, apply mitigation and implement control measures for residual risk (set objectives, minimum requirements, etc.)
- Manage SHEQ compliance within the Process through effective use of the Toolbox
- Utilise the Integrated Management System (IMS) to initiate, investigate and report SHEQ status
- Ensure an enabling climate/culture
- Maintain labour stability by minimising labour turnover
- Labour complement in line with budget
- Ensure IDP’s are linked to performance results and implemented as per plan
- Manage performance against set targets and competencies
- Conduct career discussions and implement actions with all identified talent (quarterly)
- Ensure discipline is maintained (absenteeism, lateness, overtime, misconduct, etc.)
- Coach and counsel people to ensure improved performance levels
- Conduct recruitment interviews
- Ensure Customer Satisfaction
- Proactively seek ways of improving equipment reliability, planned maintenance and physical maintenance in the plant
- Initiate task list reviews
- Develop maintenance plans (frequencies, maintainable items)
- Initiate plan review and review maintenance plans
- React swiftly to any plant stoppages involving instrumentation equipment or automation faults, report all stoppages to the Superintendent
- Backup all instrumentation software programs and ensure availability thereof
- Ensure plant availability
- Perform Pareto analyses, correlation analyses and report top 5 chronic losses
- Interview production personnel with regards to trips and artisans with regards to repetitive trips
- Arrange RCFA investigation and facilitate the problem-solving session
- Analyse alternative solutions and recommend best solution/s based on:
- HSEC (Health, safety, environmental, community) impact
- Cost - risk - benefit analysis on key equipment performance parameters
- Cost benefit to the organisation
- Recommend best solutions to problems through the change management process
- Record actions arising from RCA
- Monitor recurring failures related to implemented RCA's (KPI until close out)
- Track Condition Monitoring results
- Analyse equipment failure history
- Log equipment problems identified for further action
- Develop a list of clear problem statements and business cases for problems requiring RCA
- Monitor and share Company-wide similarities / learning opportunities by using the Intranet Sites and SAP History
- Monitor and advertise latest maintenance and technology developments
- Develop, maintain and monitor adherence to maintenance standards and specifications
- Ensure the latest techniques are being applied with respect to NDT (Non-destructive testing) and condition monitoring
- Advise in building reliability and maintainability in the design of new or modified equipment
- Develop detailed Scope of Work (SOW) for defined scope jobs
- Maintain SOW data base (Specifications, Quality Plan, Witness points)
- Provide regular feedback to the Plant Superintendent
- Monitor and maintain Chromedoc procedures
- Check uptime data, investigate and take corrective action where necessary
- Ensure that correct spares (including relevant PLC spares) and adequate quantities, are kept in stock
- Compile preventative maintenance schedule on instrumentation, measurement, control and communication equipment
- Authenticate PLC programs to ensure adequate back-up facilities are available
- Provide advice and support to team members with troubleshooting and suspected automation related defects
- Perform mean time between failure calculations and take steps to solve down-time problems
- Implement modifications according to procedure
- Monitor progress and activity on all systems, both during start up and during operation
- Monitor data/ program integrity
- Provide specialised technical advice/ assistance to customers and team members
- Log engineering requests on any plant deficiencies identified
- Maintain internal CCTV monitoring system and network
- Manage Continuous Improvement through Operational Excellence
- Degree or National Diploma in Electrical (Light Current), Electronic, Industrial Automation Engineering or equivalent
- External: 6 years’ relevant experience
- Internal: 4 years’ relevant CU experience
- Valid Driver’s License (minimum B/ Code 8)
- Experience on the Siemens PLC’s, SCADA and operating systems
- Relevant Plant experience
- Experience with IT systems and networking
- Experience on Profibus Networks
- Safety Leadership
- Innovation
- Planning, Organising & Control
- Results Orientation
- Problem Solving & Decision Making
- Relating & Networking
- Change Leadership
- Business Acumen
- Demonstrate an understanding of Process Control and I/O Systems
- Demonstrate an understanding of Siemens PLC and SCADA Systems (PCS7), PID control and Profibus Networks
- Demonstrate an understanding of PID control
- Standby, overtime, travel and carry a legal appointment
Samancor Chrome shall apply Employment Equity Principles as set out in the Company's Employment Equity Policy. Samancor Chrome is committed to building a diverse and inclusive workplace and encourages applications from suitably qualified individuals.
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