Maintenance Superintendent Instrumentation

Samancor; South Africa; On-site; ZAR 900,000 - 1,200,000; Full time

Job summary

Samancor is seeking a senior instrumentation professional to manage the instrumentation, control, and automation systems for plant operations. You will oversee calibration, maintenance, and troubleshooting to ensure optimal performance, reliability, and safety, while driving continuous improvement and cost reduction.

You will lead safety, people, and process initiatives, ensuring compliance with SHEQ standards, managing budgets, and coordinating with production teams to meet targets and SLAs.

Qualifications

• Experience in instrumentation maintenance and calibration.
• Knowledge of PLC/SCADA/DCS systems.
• Ability to conduct RCA and implement corrective actions.

Responsibilities

• Oversee calibration, maintenance, and troubleshooting of instrumentation and control systems.
• Ensure compliance with national and international instrumentation standards.
• Monitor and analyze instrumentation performance for continuous improvement.
• Plan and control instrumentation-related maintenance and shutdown activities.
• Define equipment criticality using a risk matrix.
• Develop and manage the overall instrumentation maintenance strategy.
• Ensure optimal spares management for instrumentation and control systems.
• Manage root cause analysis outcomes and sustain improvements.
• Select and manage vendors for instrumentation and automation solutions.
• Conduct planned job observations for compliance and efficiency.
• Review and update the plant’s instrumentation maintenance strategy annually.
• Ensure adherence to instrumentation work management principles.

Skills

Instrumentation design

Process control optimization

Root Cause Analysis (RCA)

Contractor management

Calibration and troubleshooting

Job description

To manage the instrumentation, control, and automation systems to ensure optimal performance, reliability, and safety of plant operations. Responsible for maintaining and improving current instrumentation practices, equipment, and processes to exceed operational targets and reduce costs.

Roles and Responsibilities:

SAFETY, HEALTH, ENVIRONMENT and QUALITY

• Manage SHEQ compliance within the Section through effective use of the Toolbox
• Utilise the Information Management System (IMS) to initiate, investigate and report SHEQ status

PEOPLE

Manage the Section:

• Ensure an enabling climate/culture
• Manage labour stability by minimising labour turnover
• Labour complement in line with budget
• Achieve HDSA/Female targets for the Section
• Manage performance against set targets and competencies

Ensure IDP’s are linked to performance results and implemented as per plan

• 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

CUSTOMERS

Jointly define annual Service Level Agreements with plant production personnel.

Put systems and controls in place that will ensure that the plant is maintained:

• at specified performance and within prescribed technical & legal requirements,
• that will permit a safe and environmentally acceptable operation, and
• to meet the required production-rated capacity at minimum life cycle costs

BUSINESS PROCESSES

Instrumentation Management:

• Oversee calibration, maintenance, and troubleshooting of all instrumentation and control systems.
• Ensure compliance with national and international instrumentation standards.
• Monitor and analyze instrumentation system performance for continuous improvement.
• Plan and control instrumentation-related maintenance and shutdown activities.

Maintenance Support:

• Define equipment criticality using a risk matrix.
• Develop and manage the overall instrumentation maintenance strategy.
• Ensure optimal spares management for instrumentation and control systems.

Problem Solving and Implementation:

• Ensure root cause analysis (RCA) outcomes are evaluated, implemented, and sustained.
• Select and manage vendors for instrumentation and automation solutions.

Work Execution:

• Conduct planned job observations for compliance and efficiency.
• Review and update the plant’s instrumentation maintenance strategy annually.
• Ensure strict adherence to instrumentation work management principles (planned maintenance, adherence to schedule, breakdown reduction).
• Manage instrumentation assets to maximize plant availability and minimize costs.
• Ensure adherence to engineering standards and specifications.
• Standardize instrumentation spares and installations across the plant.

Budgeting:

• Prepare Maintenance budget per equipment
• Consolidate Maintenance budget per plant
• Monitor plant Maintenance budget
• Action variances of actual to planned costs
• Monitor Over/Under Maintenance

Behavioural Competencies:

• Safety Leadership
• Innovation
• Leadership
• Planning, Organising & Control
• Results Orientation
• Problem Solving & Decision Making
• Aligning Performance for Success
• Communication
• Change Leadership
• Building Strong Teams
• Business Acumen

Workplace Competencies:

Skills:

• Required training as per training matrix
• Soft Skills as identified per department / level
• Instrumentation system design and maintenance
• PLC, SCADA, and DCS system management
• Process control optimization
• Calibration and troubleshooting
• Root Cause Analysis (RCA)
• Contractor and project management
• Compliance with industry standards and regulations

Knowledge:

• Instrumentation system design and maintenance
• PLC, SCADA, and DCS system management
• Process control optimization
• Calibration and troubleshooting
• Root Cause Analysis (RCA)Contractor and project management
• Compliance with industry standards and regulations