Mechanical / Maintenance Foreman

SUMMARY:
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POSITION INFO:

We are seeking the services of a highly capable Mechanical & Maintenance Foreman.
The incumbent is responsible for minimizing plant downtime, improving equipment reliability and extending the operating life of machinery through the effective and efficient execution of all mechanical maintenance activities.

The position reports to the Technical Manager.
The incumbent must collaborate effectively with Line Engineers, Production Managers/Supervisors, Maintenance Planner, and Artisans to maximize plant and equipment availability.
Provide strong and focused leadership to the mechanical and maintenance team, as well as expertise in implementing and maintaining world-class maintenance best practices.

KEY PERFORMANCE AREAS:
Responsibilities include, but are not limited to the following:

Deliverables:

• Attend Daily Operations Meetings and together with production personnel ensure that the 24-hour operating window is secured by addressing priority equipment repairs.
• Plan and execute all breakdown repairs without delay.
• Identify causes of equipment failures and repetitive repairs by completing RCFA page 1’s and page 2’s for all mechanical failures. Agree corrective actions with the plant engineers.
• Champion the implementation of proactive maintenance and the elimination of reactive maintenance by implementing preventive and predictive maintenance programs.
• Develop, review, and agree on a weekly maintenance plan with the Maintenance Planner.
• Ensure the effective execution of the weekly maintenance plan.
• Plan, prepare and oversee the execution of monthly maintenance shuts. Ensure that there are no shut overruns.
• Reduce reaction times to breakdowns (MTTR) and increase mean time between failures (MTBF) through the effective implementation of maintenance best practices, systems and procedures.
• Meet with suppliers, contractors and 3rd party inspectors when required.
• Do general daily administrative tasks and weekly/monthly reports.
• Perform standby duties when required and give assistance with after hour breakdowns.
• Perform any work that the engineering leadership team may assign from time to time

Quality:

• Ensure no maintenance rework by ensuring that work performed by internal artisans and external service providers are executed to the agreed standard.
• Regularly review and maintain the maintenance system (task lists and PM schedules).
• Develop work instructions through own and subordinates’ input to standardize tasks and spares requirements following World Class Manufacturing best practices.

Cost:

• Control maintenance costs effectively and prevent as far as possible over expenditure.
• Identify critical spare requirements and ensure the availability of these spares at all times.
• Liaise with store personnel i.e. spares holding/storage and stock requirements.
• Visual display with graphics the Maintenance team performance (costs, effectiveness, and productivity).

Health, Safety and environmental:

• Partake in on site Safety Program and conduct regular safety talks, toolbox inspection and ensure lifting equipment is inspected regularly.
• Ensure that all maintenance work is executed in a safe and efficient manner.
• Maintain high work and safety standards within area of responsibility.
• Ensure plant housekeeping is of a high standard by implementing 5S principles and practices in area of responsibility.

People:

• Manage the maintenance personnel under his control through proper guidance, supervision, inspection and discipline.
• Assist with training, coaching and general development of subordinates.
• Maintain open channel communication with subordinates through daily meetings for two-way feedback.
• Perform bi-annual performance appraisals of mechanical artisans.
• Enforce World Class Manufacturing principles onto subordinates and use WCM tools daily as Foreman - Lead by example
• Maintain a high standard of time management of self and subordinates.

QUALIFICATIONS/SKILLS AND EXPERIENCE:
• Matric or equivalent
• Mechanical Trade Test passed
• A National Diploma or B.Tech in Mechanical Engineering would be advantageous
• Have a minimum of 5 years maintenance supervisory experience in a heavy engineering and continuous manufacturing process environment
• Have a high level of understanding of World Class Manufacturing tools, processes, and systems
• Ability to do trouble shooting and present solutions in a fast-paced pressurised environment
• Have knowledge of all the legal requirements of the OHS Act, BCEA, LRA and other legal requirements

PERSONAL ATTRIBUTES:

• Self-starter, energetic and highly motivated individual with superior analytical capabilities and an intense desire to identify and solve problems.
• Highly computer literate (ERP/MRO/CMMS/MS Office)
• Excellent communication skills and leadership qualities.
• Ability to identify, visualize, articulate, and deploy plant maintenance improvement solutions.
• A person with high integrity and able to make decisions under pressure.
• Prepared to work outside normal working hours and do standby duties.
• Able to delegate effectively and empower subordinates by giving them real responsibility and authority to use their own initiative and discretion (within boundaries), and to be accountable for their own results.
• Be neat and well organized.