Bulyanhulu Gold Mine seeks to appoint a Mechanical Foreman at the Gold Processing Plant. The “Mechanical Foreman”, ensures that all scheduled and unscheduled mechanical maintenance activities for the Gold Plant, TSF Dam and Fire suppression system at BGM are properly planned and executed in a safe and efficient manner. This is to ensure required performance of critical assets is achieved, whilst also meeting the maintenance budget.
KEY RESULT AREAS/ESSENTIAL FUNCTIONS
• Spend significant time in the field – “visible felt leadership” – interacting with the workforce, ~30% of working time.
• Set and enforce a high standard of housekeeping in all work areas to provide a safe and healthy workplace for all employees and contractors.
• Review and sign-off on JSA’s/SOP’s ensuring risks are identified and mitigated. Has the authority to stop a job that does not meet these two criteria.
• Review hazard ID and incident reports (from BGM database) and provide feedback as appropriate.
• Conduct quality incident investigations (injury, significant near-miss and equipment damage), complete with detailed RCA (root cause analysis) and practical corrective actions. Ensure that the corrective actions are effectively implemented and tracked.
• Establish and refine maintenance strategies for the Gold Plant, in consultation with Process, Maintenance Planner and contractors/OEM’s to ensure that PM’s and other routine maintenance activities will deliver the desired equipment performance – e.g. equipment availability/reliability targets.
• Review (with Supervisor and Maintenance Planner), sign-off and execute weekly maintenance schedule to ensure all priority maintenance activities are prioritised and managed effectively. Has the authority to prioritise jobs.
• Report Work Management KPI’s to assess compliance to the schedule and associated work efficiencies, including the effective management of backlog.
• Develop annual budget with support from the Maintenance Planner. Report actual costs versus budget on a monthly basis and explain variances.
• Manage annual leave, sick leave, etc – capacity updated (via Maintenance Planner) in EMPAC – for the crew. Manage the roster of shift fitters to ensure coverage at all times, with the authority of approving annual leave.
• Complete annual performance reviews for all direct reports, in consultation with the Leading Hand.
• Ensure that succession planning for key roles is in place.
• Coordinate the updating of the crew’s training matrix through the Training Department and ensure that all direct reports are completing an appropriate level of training to be deemed competent for all tasks that they are assigned.
• Assume the role of shift Supervisor during plant shutdowns to ensure 100% coverage.
Initiate/implement plant improvement trials (e.g. “Pump Improvement Team”) – using the Ideas Management System.
• Attend daily Production meetings, weekly downtime review meetings, weekly PM Review Meeting - implement assigned actions from any of these meetings.
KEY RESULTS AREA & MEASURES
• Safe and healthy working environment with a high standard of housekeeping. Targeting “zero recordable incidents” for the year.
• Focus on “visible felt leadership” by interacting with employees and contractors “in the field” (minimum of 30% of working time).
• Excellent and demonstrated personal commitment to safety & health - completing a minimum of two SHO’s (Safety Hazard Observation) per month and ensuring any findings are documented and actioned.
• Commitment to continuous improvement by ensuring that all assigned actions that arise from incident investigations, maintenance/reliability improvement teams, etc. are implemented in a safe and timely manner.
• Quality, proactive maintenance execution delivered based upon well defined and practical maintenance strategies. The effectiveness of these strategies demonstrated by achieving the weekly Work Management KPI targets as defined by the Gold Plant Engineer/Superintendent – for planned versus unplanned work ratio; scheduled work completion and PM completion.
• Excellent plant/equipment reliability/availability is also a direct consequence of good maintenance strategies and effective maintenance execution. Annual targets set by the Gold Plant Engineer/ Superintendent.
• Zero-based and realistic annual maintenance budget in conjunction with rigorous cost management; specifically delivered through optimized maintenance planning, adherence to Supply policy, contractor management and quality maintenance execution. All monthly costs to be within ± 5% of budget and all variances to be thoroughly explained/documented.
• Employee retention and development supported by completing all annual performance reviews for direct reports in a timely manner. Ensuring that all direct reports are completing an appropriate level of training to be deemed competent for all tasks that they are assigned. Succession plans are in place for key roles within the crew
MAJOR CHALLENGES
• Ensuring the weekly maintenance plan is complied with whilst addressing equipment failures and other sources of unplanned work. The effective balance of planned work and unplanned work is an essential aspect of maintenance execution, and one that needs close attention in order to achieve availability targets.
• Maintenance cost management is fundamental to all aspects of maintenance. The role of Mechanical Foreman must ensure that all costs are controlled in order to meet the maintenance budget, but also be aware of the effect Availability has on profit margin to the business, particularly with respect to Critical Plant. This can be a significant cost to the business, often overshadowing maintenance cost. A major challenge is to ensure that maintenance is undertaken in a manner which represents the best investment to the business
WORK EXPERIENCE
ESSENTIAL
• Demonstrated safety leadership for both self and for a team
• 5 to 10 year’s practical experience in a maintenance environment, preferably in mining/heavy industry and Gold Plants
• Minimum of 2 years frontline supervisory experience, preferably in a mining/ heavy industry environment
DESIRABLE
• Experience with computer-based maintenance planning/scheduling
• Experience working in a minerals processing plant
QUALIFICATIONS
ESSENTIAL
• Mechanical trade
• Driver’s licence
DESIRABLE
• Technical qualification in Maintenance Planning/Asset Management
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