RELIABILITY SPECIALIST

THE ROLE

Reporting directly to the Fixed Plant Maintenance Superintendent, the incumbent needs to take full responsibility and accountability for all areas related to the maintenance reliability and systems across the Process Plant and Fixed Assets.  
The aim of the position is to ensure that all items are addressed in terms of mechanical and electrical reliability to comply to set safety and legal compliance standards.

KEY ACCOUNTABILITIES

Key responsibilities include:

• Leadership and mentorship of the Reliability Team
• Manage the equipment availability and reliability data 
• Forecasting equipment component life
• Lead the Defect Elimination process
• Lead the Condition Monitoring and Precision Maintenance functions
• Lead the Lubrication functions
• Manage the FPM Continuous Improvement Projects and Initiatives

Leadership and Mentorship of the Reliability Team

• Identify skill gaps of Reliability Team members, Artisans and Technicians and identify training requirements.
• Provide coaching and mentorship of Reliability team members.
• Ensure that all safety standards are always complied with and that all Process Maintenance staff are fully trained in terms of safety processes and procedures.
• Development and of a highly qualified and competent team through scrutinizing existing maintenance and reliability processes and workflows.
• Need to be able to act as a Back-to-Back within the Process Maintenance section and be able to ensure continuity in terms of ongoing projects.
• Contractor management as and when required as part of continuous improvement projects.
• Any other maintenance and engineering related task that might be required from time to time in the Process maintenance section.
• Use Lean processes to identify Waste and implement corrective actions. (re-work, wasted time, Inventory levels etc.)

Manage the equipment availability and reliability data 

• Maintain a register of downtime and loss events.
• Compile reports (weekly, monthly, quarterly, and yearly plant performance), for key assets and processes.  Reports to include:  Availability, MTBF, MTTR, Pareto Analysis and identification of chronic repeat failure issues.
• Ensure that monthly reporting and cost reviews are accurately completed.

Forecasting equipment component life

• Set up routine inspections to measure and assess the component condition.  Use the data to forecast the remaining component life of key equipment including:  Crusher Liners, Apron Feeders, Vibrating Grizzly Screens, Mill Feed Chutes, Trommels, Transfer Chutes, Conveyor Belts, Cyclone Feed Pumps and Tailings Pumps, critical Slurry Pipelines.
• Support with routine inspection on Leach tanks, BIOX reactor tanks and Thickeners.
• Ensure reports are completed for all Reliability Inspections. 
• Provide information to the Planning Team for estimated Component Life of the installed components.
• Use the Component Life data, as an input into Zero Based Budgets.
• Support with implementing strategies to optimize the Equipment Life Cycle.  

Lead the Defect Elimination process

• Analyse Departments Reactive Maintenance to identify repeat failure issues and implement corrective actions.
• Maintain a register of RCFA investigations, reports and corrective actions.
• Update FMEA for critical equipment.
• Identify potential failures and implement a condition monitoring program.
• Update PM strategies and PM check sheets.
• Lead Root Cause Failure Analysis (RCFA), FMEA, SIR reporting and RACI Modelling for corrective actions.
• Assist Maintenance teams with diagnostic and troubleshooting support, when required.
• Support with implementation of corrective actions relating to maintenance downtime.

Lead the Condition Monitoring and Precision Maintenance functions

• Develop effective CBM strategies and Preventative Maintenance tactics.  
• Coach and develop team members skills in CBM techniques including: Vibration Analysis, Oil Analysis, Acoustic Emission Monitoring, Thermography and Visual Inspection.  
• Develop Safe Work Instructions for team activities.
• Ensure CBM tools and maintained and periodically calibrated.
• Train and support the maintenance team in precision alignment and maintenance techniques.

Lead the Lubrication function

• Ensure lubrication registers are developed, maintained and routinely optimized.
• Lead and coach team members to ensure lubrication of equipment is performed to the required quality.
• Continuous improvement of the lubrication practices.

Manage the FPM Continuous Improvement Projects and Initiatives

• Owner of the Management of Change (MoC) for the Fixed Plant Maintenance Department.
• Maintain a register of continuous improvement projects and initiatives.  Capture and record the initiative benefits. 
• Support with Compiling the Scope of Work for planned and unplanned maintenance as well as projects.
• Management of special projects and liaison with different Stakeholders to ensure maximum efficiency and minimum downtime.
• Costing of mechanical and electrical parts and components as part of projects.
• Ensure that Capital and Operational budgets are compiled, communicated, and managed within set timelines.
• Ensure that minor and major planned maintenance is budgeted, scheduled, and executed in a timely manner.
• Analyse work order plan time versus actual time and make recommendations and changes.

Safety Management

• Demonstrate personal commitment in regard to safety and environmental and Social Responsibility practices.
• Ensure every person within the team is fit for work.
• Ensure that agreed procedures, safeguards and controls are applied and used.
• Ensure all activities are conducted safely and in accordance with Company standards and procedures
• Ensure hazard management plans are observed. 
• Keep statutory and internal reporting as required.
   

KEY REQUIREMENTS

Education:

• Recognised Mechanical Engineering Diploma or Degree.
• Relevant technical qualifications related to reliability standards.
• Relevant recognised training in Condition Based Maintenance techniques:
  • Vibration Analyst CAT II is preferred.
  • Machinery Lubrication 1 (MLA1 or MLT1) is preferred.

Relevant experience:

• Minimum 6 years-experience in a Process Plant environment.
• Mining industry experience preferable.
• Process Plant related management experience.
• Multi-skilled with good knowledge and understanding of all areas of a Gold Processing Plant.
• High-level of knowledge of local competencies.
• French / English language skills preferable.
• Working experience with Microsoft Office.
• Experience of working effectively in a senior management team environment.
• Experience working in multicultural environment.
• Able to communicate effectively at all levels of the organisation and build effective relationships and networks.
• Demonstrate strong conceptual skills and be capable of developing lateral and practical solutions.
• Ability to respond to a changing work environment
• Ability to manage multiple projects and tasks at the same time.
• Reputation for integrity and ethics.
• Demonstrated leadership skills.
   

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