Reliability and Maintenance Manager

Astron Energy South Africa (Pty); Milnerton; On-site; ZAR 1,200,000 - 1,900,000; Full time

Job summary

Astron Energy South Africa (Pty) seeks a senior Reliability & Maintenance leader to own the refinery's preventive, predictive and corrective maintenance strategies. You will drive the reliability programme, lead turnaround delivery, and oversee warehouse and inventory to sustain asset availability.

You will push for RCA/RCM driven improvements, manage safety and cost, and partner with capital planning for new assets. A strong background in refinery maintenance is essential.

Responsibilities

• Own the preventive, predictive and corrective maintenance strategies and the reliability programme.
• Direct maintenance planning and execution, lead turnaround and on‑stream maintenance delivery.
• Drive reliability improvement through RCM and bad-actor elimination.
• Oversee warehouse and maintenance inventory to support maintenance and turnaround delivery.
• Manage budgets and monitor expenses within approved budgets.
• Promote maintenance excellence through KPI monitoring and performance analysis.
• Interface with capital planning and pre-start reviews for new assets.
• Ensure safety, health, environment and quality compliance across activities.

Skills

Maintenance planning

RCM

FMEA

Predictive maintenance

Turnaround planning

Spares and inventory management

KPI monitoring

Budget control

Tools

Reliability software

SAP or CMMS

Job description

Ensure the safe, reliable and cost-effective maintenance of refinery assets by owning the preventive, predictive and corrective maintenance strategies and the reliability programme that underpins them. The role directs maintenance planning and execution, leads turnaround and on-stream maintenance delivery, drives reliability improvement through RCM and bad-actor elimination, and oversees warehouse and maintenance inventory: sustaining equipment availability, ensuring spares and materials availability, and optimising maintenance cost across the refinery.

Strategic Implementation

• Translate strategy into operational initiatives with measurable business outcomes and targets.
• Facilitate the development of best practice in operations and service excellence.
• Own the reliability strategy for the refinery, defining Reliability Centred Maintenance (RCM) scope and system selection for Preventative Maintenance (PM) analysis.
• Accountable for the RCM study - conduct Failure Mode and Effects Analysis (FMEA), determine equipment criticality and select PM and Predictive Maintenance (PdM) task strategies.

Operational Effectiveness

• Establish and manage a comprehensive Reliability Programme, including Root Cause Analysis (RCA), FMEA and RCM.
• Implement predictive and condition-based monitoring technologies to identify equipment issues before failures occur.
• Manage preventive and corrective maintenance for all refinery assets, ensuring minimal disruption to operations.
• Lead maintenance planning and scheduling to optimise resource utilisation, spare-parts management and cost control.
• Manage turnaround and shutdown planning and execution, ensuring safe and efficient delivery within budget and schedule.
• Add day-to-day delivery, running processes, monitoring performance, managing exceptions.
• Drive standardisation of maintenance procedures and ensure compliance with company and industry standards.
• Promote maintenance excellence through KPI monitoring, benchmarking and performance analysis.
• Own on-stream Turnaround delivery, including technical approval to proceed, equipment handover and reinstatement, and post-TA analysis with capture of lessons learned.
• Drive maintenance performance through monthly stewardship of Rolling Work Programme (RWP) metrics and structured resolution of chronic bad actors.
• Direct warehouse and maintenance inventory management - ensuring spare parts, materials and critical stock are available to support maintenance execution and turnaround delivery.

Financial Management

• Manage budgets and monitor expenses ensuring expenditure is within approved budgets.
• Manage all direct maintenance and maintenance-overhead costs for the refinery, ensuring expenditure is within approved budgets.
• Monitor and report on refinery maintenance costs (direct and overhead), and prepare annual maintenance cost forecasts for the business plan cycle.
• Secure technical and budget approval for the Turnaround, and ensure maintenance inventory and spares holding are optimised against working-capital and carrying costs.

People Management

• Provide direction and define objectives to be achieved in area of responsibility.
• Manage performance of direct reports ensuring agreement of annual goals and measuring performance against agreed goals and addressing non-performance issues.
• Deploy people management processes effectively, in line with Company policies, procedures and prevailing improvement initiatives.
• Drive operational excellence through area of supervision.
• Oversee resource deployment to ensure adequate cover and resilience in the team.
• Promote, support, and encourage team members to live the Company values.
• Drive a culture of high performance and accountability and encourage team members to live the Company values.
• Build reliability and maintenance capability across the team - superintendents, leads and engineers - through coaching, technical development and succession planning.

Safety, Health, Environment and Quality

• Ensure compliance with all Safety, Health, Environmental and all other applicable regulatory statutes, and all other safety and quality processes for the area of responsibility/work.
• Steward OMS within Astron Energy to ensure continuous improvement.
• Collaborate with SHEQ teams to maintain compliance with environmental and safety standards.
• Ensure compliance with statutory inspection, certification and pressure-equipment regulations for maintainable assets.
• Accountable for contractor Occupational Health (OH) compliance across reliability and maintenance activities.

Stakeholder Relationship Management

• Identify, build and nurture trust and collaborative relationships with internal and external stakeholders.
• Accountable for reliability input to capital planning - hand over to operations, commission and conduct pre-start reviews for new assets.
• Interface with the Technical Manager on fixed-equipment integrity, RBI/IMP outcomes and catalyst strategy that inform maintenance planning.
• Manage technical service providers and Origin