Maintenance Specialist Belts (North West) at Samancor Chrome

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.

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
• Ensure the legislated safety, health and environmental standards are maintained 
• Perform FMECA and HIRA analyses on new plant equipment 
• Regularly review the FMECA and HIRA analyses on existing plant equipment

PEOPLE:

Supervise the Team:

• Ensure an enabling climate/culture
• Maintain labour stability by minimising labour turnover
• Labour complement in line with budget 
• 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:

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

BUSINESS PROCESSES:

Maintenance Support:

• Initiate task list reviews
• Develop maintenance plans (frequencies, maintainable items)
• Initiate plan review and review maintenance plans

Maintenance Data Analysis:

• Perform Pareto analysis, correlation analysis and report top 5 chronic losses
• Interview production personnel w.r.t. trips and artisans w.r.t. repetitive trips

Operational:

• Ensure recognised and proper maintenance of the Conveyor Belt system to obtain 85% availability.
• Ensure that the SAP PM data and work management meets Samancor Chrome standards at all times
• Monitor corrective maintenance workload vs available manpower
• Coach and mentor team members on effective Conveyor Belt system maintenance management 
• Create quality awareness and quality service awareness within the team
• Provide regular feedback to the Engineer
• Monitor and minimize overtime worked by team members
• Compile and submit monthly Conveyor Belt performance report
• Monitor and maintain HQMS procedures

Conveyor Belt Availability / Reliability:

• Check uptime data, investigate where necessary and take corrective action
• Keep record of breakdowns, callouts, spares usage, etc. for all Conveyor Belt systems.
• Become totally integrated into the mining team to provide a comprehensive Conveyor Belt support service
• Ensure that relevant Conveyor Belt spares and adequate quantities are kept in stock, and devise action plan to handle emergency situations
• Establish a practical office management and filing system to promote good administration and record keeping.

Prioritise and plan work within the team structure

• Compile preventative maintenance schedules on Conveyor Belt equipment.
• Perform mean time between failures calculations and take steps to solve down-time problems
• Implement modifications / upgrades / major repairs according to procedures

Standby:

• Perform senior standby duties in area of responsibility
• Report any Conveyor Belt breakdowns which have the potential to or has resulted in a lost blast or production loss during call outs immediately to the Engineer
• Provide specialised on-site assistance to Belt personnel if requested

Solve problems and implement solutions:

• Arrange RCFA investigation and facilitate the problem-solving session

Analyse alternative solutions & recommend best solution/s based on:

• HSEC 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 (CM) 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 specification

Work Analysis:

• Ensure the latest techniques are being applied with respect to NDT and condition monitoring
• Advise in building reliability and maintainability in the design of new or modified equipment
• Ensure sustained FLAC improvements

Contractor Management:

• Develop detailed scope of work for defined scope jobs

Rotables Management:

• Maintain Scope of Work data base (Specifications, Quality Plan, Witness points)

Costs

• Regularly review cost reports, investigate over-expenditure and take corrective action

Overtime control

• Strive for continuous improvement in the Belts effectiveness and availability through implementation of cost-effective technology
• Keep abreast of latest equipment / technologies and trends.

GROWTH

• Manage Continuous Improvement through Operational Excellenc

Requirements

MINIMUM REQUIREMENTS AND EXPERIENCE:

• Degree B.Eng. / BSc (Mechanical or Electrical Engineering) or N6 Engineering or National Diploma in Engineering studies
• 6 years’ relevant experience

Additional:

• Trade Certificate (Boilermaker / Fitter / Electrician)
• Experience in Conveyor belt construction and maintenance.

KNOWLEDGE:

• Demonstrate understanding of asset reliability improvement using root cause analysis and maintenance performance evaluation.

BEHAVIOURAL COMPETENCIES:

• Safety Leadership
• Innovation
• Planning, Organising & Control
• Results Orientation
• Problem Solving & Decision Making
• Relating & Networking
• Change Leadership
• Business Acumen