Utilities Foreman

SUMMARY:
JOB DESCRIPTION: Utilities Foreman
Location: Port Elizabeth (Gqeberha), Eastern Cape
Department: Engineering & Utilities
Reporting To: Engineering Manager / Technical Manager
Employment Type: Permanent
Salary : R65 000 Gross per Month

1. Role Purpose

POSITION INFO:

1. Key Responsibilities

• Oversee daily operations of all utilities equipment including:
  ✔ Industrial boilers (5-ton units)
  ✔ Ammonia refrigeration plants, glycol chillers & cooling towers
  ✔ High-pressure compressors (up to 40 bar) and air dryers
  ✔ Standby and production generators
  ✔ Water treatment systems (sand filters, multi-stage filtration, chlorination systems)
• Ensure optimal performance of utilities through monitoring, inspection, and corrective action.
• Conduct troubleshooting on mechanical, electrical, pneumatic, hydraulic, and instrumentation systems.
• Maintain accurate running hour logs, utility performance records, and compliance documentation.

• Implement, manage, and optimise preventative maintenance schedules for all utilities equipment.
• Prioritise and allocate maintenance tasks to artisans and technicians.
• Ensure critical spares availability and stock control to prevent downtime.
• Maintain calibration schedules for all instrumentation, sensors, transmitters, and control valves.
• Oversee maintenance shutdowns, planned servicing, and statutory inspections (boiler, pressure vessels, safety equipment).

• Support PLC/HMI troubleshooting (Siemens S7, VSDs, single-loop controllers).
• Assist with instrumentation calibration, settings, and fault finding (flow, level, pressure, temperature).
• Maintain backups of PLC programs, configurations, and control system documentation.
• Ensure integrity of automation systems used within utilities (burner controls, ammonia controls, pump systems, dosing systems).

• Ensure all utilities operations comply with OHS Act, boiler regulations, and relevant SANS standards.
• Enforce permit-to-work systems, lock-out procedures, and confined space entry protocols.
• Maintain up-to-date safety files, service records, and statutory inspection certificates.
• Attend safety audits, quality audits, and participate in root cause investigations.

• Supervise utilities artisans, technicians, and contractors.
• Conduct daily planning meetings and allocate work based on production priorities.
• Report utilities issues, downtime, and solutions to the Engineering Manager.
• Manage overtime, attendance, shift planning, and performance of the utilities team.
• Prepare utilities reports, maintenance summaries, project updates, and compliance logs.

• Identify and implement utilities-related improvement projects to reduce downtime and energy consumption.
• Lead cost-saving initiatives on water, steam, air, ammonia, and refrigeration systems.
• Support commissioning of new utilities equipment and expansions.
• Optimise plant reliability through data-driven decision-making (5 Why’s, failure analysis, FMEA).

• Trade Test: Instrumentation Mechanician (essential)
• or Millwright
• or BTech Mechanical Engineer
• Technical qualifications: N6 or higher (advantageous)
• Boiler operation or boiler familiarisation certification (advantageous)
• Pneumatics, hydraulics, and PLC-related certificates beneficial

• 10+ years utilities and maintenance experience in manufacturing/FMCG/processing sectors
• Strong exposure to boilers, refrigeration plants, chillers, compressors, and water treatment systems
• Experience leading maintenance teams or utilities departments
• Proven track record of reducing equipment downtime and improving plant performance

• Instrumentation fault finding & calibration
• PLC (Siemens S7) & HMI exposure
• Pneumatic & hydraulic systems
• VSDs & control valves
• Root cause analysis & problem-solving
• Utilities compliance and statutory inspections
• Strong understanding of mechanical and electrical systems

• Strong leadership and mentoring ability
• High attention to detail
• Excellent communication & reporting skills
• Ability to work under pressure in high-volume manufacturing environments
• Proactive, solution-driven and safety-conscious

• Utilities uptime & availability
• Planned vs. unplanned downtime
• Compliance with boiler, compressor, ammonia & OHS regulations
• Execution of preventative maintenance schedules
• Cost control & budget adherence
• Spares management effectiveness
• Performance of utilities team
• Reduction of energy & water usage