Senior Engineer

JOB PURPOSE:

• To apply deep specialist technical and operations knowledge and skills to make recommendations to maximize the reliability, availability and performance of complex industrial equipment and systems to optimize return-on-investment (ROI).
• To plan and recommend the Departmental preventative maintenance program.

RESPONSIBILIT:

2.1 Plan and recommend a Preventative Maintenance (PM) Program to maximize the reliability, availability and performance of complex equipment to optimize ROI.

• Understand the business and production needs and constraints. Conduct FMECA / RCA (see 2.5).
• Develop the Maintenance program (preventative maintenance and major maintenance) to optimize business and maintenance outcomes. Develop the costing model.
• Validate and Optimize PM Task Lists in coordination with department maintenance team.
• Participate in departmental lean board and weekly scheduling meetings for Reliability input.
• Reporting and presenting feedback for plant wide Reliability meetings.
• Identify and select spare parts. Update the spare parts list and the Bill of Materials.
• Develop the System Performance Testing approach.
• Implement the reliability strategy and costing model.
• Review and improve the maintenance program – asset life assessment and improvement.
• Manage the Asset evaluation program.

Leading the Reliability Meetings to determine Reliability Projects:

• Perform detailed analysis to inform recommendations on Reliability Projects; calculate the payback period and ROI.
• Prepare data and reports to inform management decision-making.
• Facilitate the meetings to determine priorities and select reliability projects.

2.2 Control and maintain documentation to ensure accurate complete, up-to-date records and SOPs:

• Ensure documentation is maintained (filed; updated; version control implemented) Support the leaders to develop SOPs.

2.3 Performance monitoring: develop, monitor and report reliability KPIs to enable the leadership to track performance and make decisions on ways to improve performance,
including asset efficiency and maintenance efficiency.

2.4 Apply specialized technical skills to develop recommendations to maximize the reliability, availability and performance of complex equipment to optimize return-on-investment (ROI).

• Conduct failure mode and effects analyses to identify the critical plan failure modes in a systemic and structured way . Complete Root Cause Analysis for asset failures.
• Examine each to determine the optimum maintenance policy to reduce the severity of each failure.
• Investigate to determine the reliability required for the particular situation considering the cost limitations for equipment up/down time, repair or replacement costs, weight, size, and availability of materials and equipment.
• Determine the cost advantages of alternative action plans to comply with the Department's demands for reliable processes and equipment in order to avoid failures, or, action tasks to address problems or to optimize production outcomes.

Action daily failure analysis:

• Extract and analyses data on equipment failure; recommend action to reduce failure
• Ensure the appropriate equipment modifications are actioned.

Develop analysis methods:

• Apply analysis methods for determining the reliability of components, equipment, and processes.
• Acquire data and analyze the data.
• Prepare diagrams, charts, drawings, calculations, and reports for defining reliability problems and make recommendations for improvements.

2.5 Deliver coaching, training, technical advice and support to the maintenance teams to enable the teams to quickly and efficiently return the equipment to full operating capability, and to build team capability and increase performance.

• Coach Technicians on safety, technical and operational procedures, including risk analyses, to ensure high standards of technical capability and performance.
• Assist Technicians to trouble-shoot.
• Perform the role of technical SME in at least one subject area.
• Educate the organization in best practices for reliability-centered maintenance.
• Develop new KPIs; engage, train and motivate the teams to deliver against the new performance goals.

2.6 Lead, motivate and develop a small team to deliver high-quality reliability management services

• Set individual performance objectives, action WPPs, manage performance.
• Action the disciplinary cycle if necessary.
• Action development initiatives (observe; coach; train; counsel under-performers)

Manage time and attendance while maintaining accurate SAP records.

2.7 Action the SA Environment, Health & Safety (EHS) procedures to ensure safety and compliance

Examples: Participate in the Safe-Start meeting, coach others on EHS routines, action contractor permits and work permits, lead safety interactions, ensure the continuous application of 5S principles, ensure equipment maintenance and cleanliness and generate appropriate equipment notifications.

• Continuously action the SA EHS procedures.
• Analyses and mitigate EHS risks inherent in maintenance plans, tasks and projects.
• Know and apply the SA housekeeping principles and procedures (5S) to maintain the work areas and storages in a safe, efficient condition.

REQUIREMENTS:

Essential qualifications, knowledge, experience and skills:

• A degree in Engineering Electrical, Mechanical and a minimum of 6 years of relevant experience,
• Very deep technical knowledge (it is not necessary to have deep process knowledge).
• Deep knowledge of the Departmental business, including the production processes, production economics, organizational structure and decision-making processes, business needs and constraints, budget, planning, legal and public relations constraints.
• EHS
  : Strong knowledge of the EHS policies, systems and management procedures required in an industrial plant. Strong commitment to EHS principles.
• SAP
  : Strong working knowledge, particularly of the PM modules.