MFC Maintenance Specialist Instrumentation

Samancor Chrome Ltd.; Middelburg; On-site; ZAR 420,000 - 540,000; Full time

Job summary

Samancor Chrome Ltd. in Mpumalanga is seeking a Maintenance Supervisor to lead RCFA investigations, drive reliability improvements and maintain instrumentation, control and automation systems to maximise plant availability.

You will supervise a team, develop maintenance plans, analyse data, and collaborate with operations to reduce downtime and safety risks.

Responsibilities

• Improve Asset Capability Assurance via RCFA on high-frequency, high-cost breakdowns.
• Maintain all measurement, automation and control equipment to minimize downtime and maximize production.
• Identify risk exposures and apply mitigation within the SHEQ framework.
• Supervise team, manage performance, conduct recruitment interviews and career development.
• Develop maintenance plans, review and adjust plans to ensure plant availability.
• Lead RCFA investigations, analyse alternatives and implement cost-benefit solutions.
• Monitor instrumentation software backups, data integrity and system reliability.
• Oversee contractor and rotables management; maintain SOW data base and specifications.
• Provide feedback to Plant Superintendent and monitor ongoing systems and CCTV monitoring.

Job description

PURPOSE OF THE JOB

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.

SAFETY, HEALTH, ENVIRONMENT AND QUALITY

• 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

PEOPLE

Supervise The Team

• 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

CUSTOMERS

• Ensure Customer Satisfaction
• Proactively seek ways of improving equipment reliability, planned maintenance and physical maintenance in the plant

BUSINESS PROCESSES

Maintenance Support and Data Analysis

• 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

Solve Problems And Implement Solutions

• 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

Work Analysis, Contractor And Rotables Management

• 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)

Operational

• 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

GROWTH

• Manage Continuous Improvement through Operational Excellence