Engineering Manager

Job purpose

To professionally lead the total Mill’s engineering functions and to ensure plant availability is maximized by implementing and managing World Class Maintenance Practises and Continuous Improvement strategies in order to achieve Safe, Operational, and Cost effectiveness business. To understand, evaluate, improve, implement, and manage systems including people, machines, equipment, parts, and controls such that all individuals return home safely, sustain or improve machine/equipment operational efficiencies, and coordinate the development of activities with respect to preventive, predictive, and corrective maintenance in accordance with the organisation’s goals. In addition to instil an attitude within the department of achieving continuous improvement and the elimination of waste within a safe and healthy working environment.

Main responsibilities

• Participate as a member of the mill’s Management Team in formulating Strategies, Plans and Budgets and in monitoring its (subsequent) performance so as to ensure that the Mill goals are achieved
• Define, implement, and report on effectiveness of Maintenance Department strategies (goals/objectives)
• Coordinate and manage start-ups of new installations in order to attain the results forecast in terms of deadlines, costs, and productivity/quality improvements
• Ensure ISO, JDE, Q Pulse are fully and effectively integrated into all department tasks
• Ensure efficient Program and control preventive maintenance work while establishing the tests to which the manufacturing equipment is to be subject to maintenance plans.
• Minimize downtime and increase machine efficiency by understanding, monitoring, evaluating, and implementing systems to improve scheduling, planning, reliability, and quality of work on all systems
• Effectively manage all sub-contractors and insure they follow all relevant legislation OSHA & Regulations, and Mill directives, especially with regard to Mill Safety and Environmental Sustainability policies
• Collaborate with Procurement by establishing the technical specifications of materials and implementing stock control measures of maintenance parts
• Proactively manage stock parts by periodically reviewing inventory turns, max/min levels, critical spares, aging reports, obsolete equipment parts and make recommendations for modifications
• Develop, justify, and manage the maintenance budget and submit monthly reports
• Manage the routine (daily, weekly, monthly etc.) processing activities typically associated with the Maintenance function at plant level in compliance with the company standards.
• Evaluate, improve, and/or implement new systems that ensure employees in the Maintenance Department have adequate(or better) trade and paper making knowledge and skills, encourage employee development and trade flexibility, provide systems to effectively co-ordinate their work with department, production, and sub-contractors, and provide guidance and support whenever necessary
• Review, on a regular basis, the processes in the Maintenance function and, with other members of the Mill’s Management Team, processes within the businesses upon which the Maintenance function is dependent, to ensure that they are delivering what is required in an effective manner
• Ensure that the entire Maintenance Team (Mechanical, Instruments and Electrical) work together and with the Production team’s towards common goals and objectives that support the Mill’s strategies
• Defines KPIs for the Maintenance Department (which are cascaded down to the individual team members) and ensure timely follow-up and delivery with monthly reports to General Manager
• Advise, in the first instance, the General Manager at the earliest opportunity of any concerns he/she may have regarding the performance of the department and/or its processes
• Strive for World Class Maintenance systems as measured within the Industry. Set the “Industry Standard”, adapting new ideas and concepts from others within and outside industry by taking advantage of our Continuous Improvement culture
• Keep up to date on new development and foster learning & development among the team; Oversee that cross training takes place among the team members. Utilize outside expertise for training whenever available
• Performs other work-related duties and project work as assigned
• Ensure, through efficient planning, that planned downtime is kept to an absolute minimum with a year on year improvement.
• Report to the General Manager daily reflecting:

       i)    Condition of plant and machinery per plant

       ii)   Plant out of commission and expected return to service

       iii)  Any at risk behaviour/accident/injuries

       iv) Other abnormalities

• Ensure that management objectives, changes and policies are carried out effectively.  Prudently communicate such selected information to the department so as to keep everyone well informed.
• Assume duties over weekends as co-coordinator as and when required.
• Apply Engineering Science to the resolution of engineering and process problems for the improved equipment availability and productivity.
• Monitor and control the effectiveness of energy usage in the Mill.
• Execute specific projects allocated from time to time.
• As a designated “Competent Person” in terms of the OHS Act, responsible for ensuring that plant and procedures within the Mill complies with all statutory requirements.
• Ensures that all projects, maintenance and production activities are conducted with due regard to the potential environmental impact it may have on the mill, or mill processes, such that they ensure compliance to all legal and regulatory requirements
• Be responsible for the implementation of SHEQ systems within the department as well as supporting and improving such systems for the mill.  Such systems include, but are not limited to, OHSAS 45001.
• Ensure adherence and compliance of environmental Act, responsible for ensuring that plant and procedures within the department as well as improving such systems for the mill.
• Ensure the efficient utilization of labour resources within his control.
• Responsible for performance evaluations, succession planning and recruitment of personnel through the Human Resources Department within the department.
• Promote mutual bi-directional co-operation and liaison between Maintenance, contractors and production personnel
• Promotes training of personnel.
• Co-ordinate resources of different skills with areas requiring their application.
• Understand the SHEQ requirement of Rosslyn mill and create a safe and healthy environment awareness
• Monitor mills performance against SHEQ requirement and correct non- conformances
• Ensure compliance with statutory requirements and mill standards and procedures.
• Identify possible site’s hazards risks and their elimination/mitigation  
• Report and investigate all incidents within department
• Manage the process for developing and maintenance of work rules and operating permits.
• Recommend replacement of uneconomical or obsolete equipment (yearly capex and renewal budget)
• Compile, motivate and manage the capital and renewals budget and cost within a budget for the Mill.
• Compile, motivate, monitors and controls departmental fixed and variable costs relative to budgets by delegating responsibility and accountability in a structured manner to subordinates.  Demand satisfactory explanations for variances.  Implements and enforces corrective actions as required.
• Submit monthly reports reflecting negative and positive cost variances from budget and reasons for such variances (Cost Report)
• Authorize the working of any overtime within the Engineering Department and make every endeavor to remain within the budget.
• Scrutinize and authorize all purchases and indent requisitions generated r.
• Scrutinize and authorize new stock and obsolete stock to ensure stock control of stores is in line with the policies and objectives of the Engineering Department.
• Instils a spirit of excellence amongst all staff with emphasis on deadlines, fostering high standards of workmanship, pride and job satisfaction.
• Maintain engineering standards for equipment and materials which have been adopted as Mill standards and recommend improvements.
• Liaises with the Plant Engineer and Operation Manager to assist, support and meet production requirements, ensuring that the principles of waste elimination through continuous improvement are fully supported by all engineering staff.
• Ensure adherence and compliance of SHEQ systems within the department as well as improving such systems for the mill.  
• Will be required to be act as the GRM2 of the mill