Maintenance Manager

• Team Leaders fulfil their safety obligations with respect to work instructions, task observations and risk assessments in order to provide a safe and healthy work environment. This includes fulfilling GMR2.7 duties as stipulated in the OHS Act.
• Control and manage the relevant maintenance budgets as agreed with the Engineering Manager to ensure planned cost outcomes are achieved.
• Implement, improving and executing the maintenance strategy, objectives and tactics in respect of the available resources to ensure optimum performance and reliability of the plants.
• Drive effective maintenance through root cause failure analyses on critical equipment and/or system failures and recommend corrective measures to prevent recurrences.
• Responsible for the accuracy of equipment database, bills of material and the asset register to ensure good data integrity and availability of equipment and/or spares.
• Manage the Engineering department interaction with the Operations/Production Department to optimise processes and improve systems with the purpose of optimising efficiencies.
• Develops guidelines and rules provide assistance and direction to plant personnel to ensure good engineering practice through documentation, quality control, and review mechanisms.
• Manage the planning and scheduling of maintenance activities in line with production requirements through subordinates by means of effective asset care systems.
• Responsible for high-level technical reports related to projects, maintenance activities, improvements and costs.
• Implement and manage approved projects and new technology and ensure compliance to standard engineering practices.
• To ensure staff are effectively managed and held accountable through performance and disciplinary procedures, and that staff are developed and mentored through the talent management and IDP processes.
• Lead and oversee projects and maintenance job on a practical level.
• Knowledge and understanding for planning statutory shutdown.

• Focuses on reliability issues and not firefighting (day to day) issues.
• Achieves Asset Mechanical Reliability (AMR) business objectives and assists businesses in meeting Asset Capability (AC) objectives.
• Participates in the facilitation and implementation of the Global Root Cause Investigation (RCI) process; serves as local SME on the application of the cause and effect methodology in all areas where reliability opportunities are identified and where the RCI triggers for reliability are met.. Validates RCI solutions/ corrective actions and assesses their effectiveness for preventing recurrence.
• Evaluates and communicates solutions for developing/leveraging as Most Effective Technology (MET) 1, 2, or 3.
• Develops and maintains a model of the unit operations, equipment, process, etc. that identifies the value of opportunities for improvement. (This long term cost of ownership evaluation can be as simple as an ExcelTM spreadsheet such as the TICA Evaluation model, RCM, or as complicated as a detailed reliability model. Identifies gaps between facility strategy, reliability model, and existing plant performance to provide input to the facility opportunity list.
• Documents the facility opportunity list. Establishes value for the reliability opportunities, utilizing facility asset utilization and maintenance costs data.
• Determines the proper work process to address the reliability opportunities on the facility opportunity list (fix the obvious, TICA, Six Sigma). Follows through with the appropriate parties to ensure effective hand-off and provides reliability input to the process.
• Evaluates and quantifies the impact projects such as equipment reconfigurations, design changes, equipment quality, operating discipline, PPM strategies, etc will have on ability to meet business needs.
• Evaluates effectiveness of the PPM program by showing quantitatively the impact of failures and PPM.
• Provides reliability input to Global Project Methodology (GPM) activities. Participates in FEL and VIP activities as appropriate; Process Simplification, Value Engineering, Maintenance Strategy, Reliability Modeling, etc.
• Uses reliability engineering principles and tools (such as Weibull, RCI, FMEA) to improve AC and AMR and long term cost of ownership of the facility.
• Participates in Facility Assessments and efforts to implement corrective action, which maintain or improve plant condition.
• Applies long term cost of ownership and reliability engineering principles in conjunction with the discipline teams and technical resource networks to design reliability into our purchasing requirements. Provides equipment reliability and performance data to the technical resource networks for evaluation of equipment performance, vendor performance, and modifications to MET level 1.
• Uses long term cost of ownership and reliability engineering principles to define spare parts strategy. Consults, as needed, with Maintenance Engineer/ Technologist and PPM Coordinator to establish spare part program.
• Develops and implements operating discipline that will improve reliability.
• Participates in reliability network activities (site and/or business as appropriate).

Assist GMR 2.1 in the execution the duties. This includes safety management, maintaining equipment, managing systems and managing people. 

The tasks include:

• To ensure legal and SHEQ compliance as per OHS Act. Emphasize continuous implementation of HAZOP and Pre-Start-up Safety Review (PSSR).
• Applying sound engineering principles to improve plant appearance, reliability and structural integrity.
• Participates in business strategic meetings, technical and projects meetings.
• Identify and manage risks that could harm the business I.e. production loss, high maintenance costs, health and safety etc.
• To use FMEA, Root Cause Analysis to prevent failure recurrence utilizing Lean Six Sigma tool.
• Maintenance of electrical and mechanical machinery applying relevant codes and standard i.e. ASME, API, SANS.
• To manage systems (Work Management, safety, man hours, budget& forecasting, Equipment Maintenance Strategy, Risk Assessments, Statutory inspections etc).
• Manage projects from feasibility studies, design phase, execution phase, final phase to hand over.
• Ensuring that all investments and R&M Capex projects are carried out in accordance with OHS Act and contract management as per in house Global Management Standard.
• Compiling projects technical specifications and liaise with engineering consultants for all projects designs and drawings.
• Projects management (Stakeholder’s management, quality assurance, documentation, risk management, cost control, safety management etc.)
• Data analysis for continuous improvement (MTBF, MTTR, bad actors, Preventive Maintenance Compliance (PCOM), Schedule Maintenance (SCOM) etc)
• Prepare and submit Capital Appropriation Request (CAR) for capital projects to improve plant reliability.
• Controlling, monitoring and monthly reporting of R&M Capex and maintenance Budget.
• Responsible for Fixed asset capitalization and depreciation.
• Identifying critical plant equipment, critical spares, obsolete items to ensure that fixed asset renewal and replacement strategy is implemented properly.
• Compile shutdown scope, plan and schedule activities.
• Plant continuous improvement for corrosion protection, structural integrity, building and civil.
• Support Reliability Centered Maintenance program, offer technical support, training and mentoring of maintenance artisans (fitters, welders, welders, electricians, instrument technicians, supervisors, storeman, reliability specialist and draughtsman
• Responsible for closing active/open Management of Change (MOC).
• Compile RFQs for suppliers and organize site briefings.
• Attend to breakdowns and do standby when required.

Outcomes from position are:

• Project management skills (idea generation, design, fabrication and installation)
• Leadership (managing self, managing contractors and artisans)
• Networking (Contractors, plant personnel and management)
• Design review (Re-rating, Fitness for service and squad check)
• Technical specification review,
• Bid clarification
• Knowledge of ASME, API, PER, SANS 347, Orion line class specifications, MOC, HAZOP, Risk assessment, HAZLOC and OHS Act.
• Problem solving

• Responsible for all static maintenance of Platformer Alky and Utilities areas.
• Generate welding Repair Work Sheet for piping and pressure vessels (boilers, heat exchangers, columns, various types of valves, tanks, reactors, flares, stacks, cooling towers, furnaces, fin fans, sand filters, air dryer, drums etc.)
• Utilizes petrochemical codes and standard for maintenance repairs (ASME B31.3, SANS 347, NACE, ASTM’s, API 710, 650 etc.)
• Preparation of shutdown scope of work for Plat Alky and Utilities.
• Root Cause Analysis for recurring failures on static equipment.
• Scoping, planning and scheduling of day to day Plant Maintenance for T-7 and T-1.
• Responsible for online leak sealing devices (injection, re-injection, clamp and box installations)
• Attend daily maintenance, production and PDR meetings.
• Responsible for closing active/open Management Of Change (MOC).
• Create purchase requisition for all new equipment for maintenance and shutdowns
• Compile RFQs for tenders and organize site briefings.
• Generate QCP repairs for all non-statutory equipment.
• Attend to breakdowns and do standby when required
• Liaise with contractors and suppliers

Outcomes from position are:

• Project management skills (idea generation, design, fabrication and installation)
• Leadership (managing self, managing contractors and artisans)
• Networking (Contractors, plant personnel and management)
• Design review (Re-rating, Fitness for service and squad check)
• Technical specification review,
• pipe calculations (minimum wall thickness, pipe integrity checks and pressure test calculations)
• Bid clarification
• Knowledge of ASME, API, PER, SANS 347, Natref line class specifications, MOC, HAZOP, Risk assessment and OHS Act.
• Root cause analysis
• Fault finding
• Problem solving

• Manage projects from design phase to close out phase.
• Inspect all rigging equipment timeously in accordance with Lifting Machines of Driven Machinery Regulation, Osh Act.85 of 1993 to ensure safe, reliability and availability.
• Generate Scope of Work for all projects
• Conduct daily safety meeting.
• Negotiate contract prices with customers in order to obtain projects contract.
• Work within project constrains (Time, Quality, Costs, Scope of Work)
• Maintain good relationship with customers.
• Ensure that my team receive competent training to be able to perform quality work.
• Compile Risk Assessments and Methods Studies for the projects.
• Generate lifting/rigging plans on 3D model.
• Assigned to design equipment for special cases
• Use calculations to select suitable cranes and rigging gear for the projects.
• Organize resources and competent rigging crew for the projects.
• Compiled detail induction manual for new employees
• Provide technical support to customers

The tasks include:

• Interacting with engineering sub-contractors to:
• Determine the most suitable subcontractor for a specific job.
• Address any technical queries related to the rigging /heavy lifting processes.
• Obtaining quotations for lifting operation from the clients.
• Compiling project costing sheets and preparing project proposal documentation for the bid.
• Addressing any queries related to the quality assurance of lifting or rigging process.
• Adhering to all other applicable company policies and procedures.

Outcomes from position are:

• Sales Engineering (To promote, perform and co-ordinate various commercial and engineering tasks)
• Leadership (managing self, managing contractors and technicians during the project)
• Networking (Contractors, plant personnel and management)
• Design review (squad check and ordering components as per drawing)
• Application engineering (Addressing any technical queries related to the product)
• Design calculations (rigging tackles, material testing and bending moments calculations)
• Project Engineering (managing and coordinating in-house and external engineering projects)

• Project management, Materials presentation, Manufacturing engineering support and quality assurance.

The tasks include:

• Shop Floor support and On Time Delivery.
• Quality Audits

The work involved in:

• Main focuses are on material supply to Transnet Engineering
• Attain all aspects of production operation including safety, scheduling, quality, and team development in assigned areas.
• Assigned to provide direction, material support, inventory planning and control to Transnet Engineering.
• Maintain product information in a tool called TeamCenter (BOM, 3D models and 2D drawings)
• Ensuring that any Engineering Changes gets updated on ERP Assist sourcing department to do material pre-qualifications
• Assigned to create work order requisitions to GE Erie plant and to our manufacturing partners in South Africa
• Generate purchase requisitions based on the production master schedule.
• Assigned to raise Non-Conformance Material Review and dispositioning of Non-conformance Materials.
• Root Cause Failure Analysis on discrepant materials
• Responsible for generating cycle counts
• Schedule, resolve issues, track material availability and advise on material usage
• Utilizes a tool called Oracle Business Intelligence (OBI) to generate materials reports for analysis.
• Design and implement processes and systems for control and replenishment of materials.
• Promote customer satisfaction and develop positive customer relationships.
• Responsible for data driven decisions and utilizing Six Sigma tools.

Outcomes from position are:

• Project management skills (idea generation, expediting, fabrication and installation)
• Leadership (managing self, managing contractors and technicians during the project)
• Networking (Contractors, plant personnel and management)
• Design review (Re-rating, Fitness for service and squad check)
• Technical specification review,
• Handling of non-conformance material
• Root cause analysis
• Problem solving

• Project management, Materials presentation, Manufacturing engineering support and quality assurance.

The tasks include:

• Shop Floor support and On Time Delivery.
• Quality Audits

Duties

• Responsible for engineering design all pump stations as per their codes.
• Supply, install and commission all the pump systems designed.
• Responsible for compiling mechanical and electrical installation instructions.
• Responsible for compiling BOQ for sewage, slurry and water pumping systems.
• Fault findings on submersible, self-priming centrifugal and non-self-priming centrifugal pumps.
• Responsible for external sales and building an ongoing relationships with the customers
• Handle quotes inquiries for different pumping systems, control systems and power supply.
• Assigned to do pre-qualification of subcontractors
• Project planning, quality and cost control.

The tasks include:

• Assist with the management and improvement of the reliability and integrity of all valves.

The work involved in:

• Daily plant problem solving
• Co-ordination and management of projects
• Leadership and supervising of artisans.
• Continuous plant improvement and modification
• Assist with strategic planning
• Preparation of shutdown scope of work
• Root Cause Analysis of failure on valves
• Equipment condition monitoring
• Comply with Eskom safety and quality control systems.
• Ensure that Scope of work is done according to Project Quality Plan (PQP).
• Responsible for verifying check lists.
• Plant walk down

• Ensure that maintenance strategies are being implemented
• Faultfinding and maintenance of vacuum pumps and compressors.
• Pneumatic systems for Locomotives: Compressors, control and operating valves.
• Compiling detail technical specifications
• Quality control of projects, machinery and installations (mechanical and electrical)
• Fault finding and failure analysis.
• Responsible for Engineering Change Request and Design Process Request.
• Responsible for ensuring that the Change Impact is fully implemented.
• Responsible for technical support to customers.
• Register item master data information on the in-house ERP system.

Maintenance of Tractors, commercial vehicle and Trucks.
Assigned to plan and generate job cards for the diesel mechanics.
Utilizes maintenance budget to organize resources for maintaining and improving production machines (TLB’s, trucks, commercial vehicles, vibration stampers etc.)
Organize relevant tools for the subordinates.
Overhaul, repair, assemble various gearboxes, engines and do fault finding on the electrical parts of the machines.
Apply Root Cause Failure Analysis on mechanical and electrical equipment failures.
Write a weekly report focusing on the financial and technical side of my work.

Power Machnies N5
Mechanotechnics N5
Eng Science N3
Eng Science N4

• Equipment condition monitoring
• Responsible for conveyor system (pulley lagging, belt splicing, coupling and drive selection, rectify take-up masses)
• Basic fault finding and service of equipment
• Use of basic measuring tools
• Responsible for sub-contract management.
• Ensure that maintenance is carried out in accordance with Quality Control Plan.
• Maintenance of vibration screens, centrifugal pumps, stackers and declaimer.
• Maintain gearboxes, hydraulic systems and cyclones.