Senior Reliability Engineer

Job Purpose

-To apply deep specialist technical and operations knowledge and skills to make recommendations to maximize the reliability,

availability and performance of complex industrial equipment and systems to optimize return-on-investment (ROI)

-To plan and recommend the Departmental preventative maintenance program

Responsibilities:

*Plan and recommend a Preventative Maintenance (PM) Program to maximize the reliability, availability and performance of

complex equipment to optimize ROI

Understand the business and production needs and constraints. Conduct FMECA

Develop the Maintenance program (preventative maintenance and major maintenance) to optimize business and

maintenance outcomes. Develop the costing model

Plan the work: action risk analyses, including EHS risks; action the task list; define materials requirements (materials,

man-hours, tools, equipment)

Identify and select spare parts. Update the spare parts list and the Bill of Materials

Develop the System Performance Testing approach.

Implement the reliability strategy and costing model

Review and improve the maintenance program

Develop the PM budget in consultation with the Superintendent

Manage the Asset evaluation program

Execute major overhauls and annual refit programs

Lead the Reliability Meetings to determine Reliability Projects

Perform detailed analysis to inform recommendations on Reliability Projects; calculate the payback period and ROI

Prepare data and reports to inform management decision-making

Facilitate the meetings to determine priorities and select reliability projects

*Control and maintain documentation to ensure accurate complete, up-to-date records and SOPs

Ensure documentation is maintained (filed; updated; version control implemented)

Support the leaders to develop SOPs

*Performance monitoring: develop, monitor and report reliability KPIs to enable the leadership to track performance and

make decisions on ways to improve performance, including asset efficiency and maintenance efficiency

*Plan and execute reliability projects (including capex projects) to maximize the reliability, availability and performance of the

equipment and to optimize ROI

Articulate the project brief, the scope of work and the requirements

Prepare the Appropriation Request. Gain approval

Set objectives; plan the tasks and activities; determine the resource requirements; determine the timeline and the

sequencing. Develop the costing model

Action risk analyses, including EHS risks

Commission and manage consultants and contractors (prepare the brief; accept and evaluate proposals; commission work;

manage the outputs; manage costs)

Analyse, monitor and control expenditure to ensure SA achieves value for the investment. Take action to correct budget

variances. Analyse, report and justify budget variances

Manage the client's expectations in relation to cost, timetable and scheduling

Fulfill the duties of the User Representative on maintenance projects

Develop the necessary Standard Operating Procedures (SOPs); consult with stakeholders on the SOP; train staff on the SOP

Maintain complete, accurate project records. Update the Master data record, including Functional Location

*Apply specialised technical skills to develop recommendations to maximize the reliability, availability and performance of

complex equipment to optimize return-on-investment (ROI)

Conduct analyses of reliability problems:

Conduct failure mode and effects analyses to identify the critical plan failure modes in a systemic and structured way

Examine each to determine the optimum maintenance policy to reduce the severity of each failure

Investigate to determine the reliability required for the particular situation considering the cost limitations for equipment

up/down time, repair or replacement costs, weight, size, and availability of materials and equipment

Determine the cost advantages of alternative action plans to comply with the Department's demands for reliable processes

and equipment in order to avoid failures, or, action tasks to address problems or to optimize production outcomes

Action daily failure analysis:

Extract and analyse data on equipment failure; recommend action to reduce failure

Ensure the appropriate equipment modifications are actioned

Develop analysis methods

Apply analysis methods for determining the reliability of components, equipment, and processes

Acquire data and analyze the data

Prepare diagrams, charts, drawings, calculations, and reports for defining reliability problems and make recommendations for

improvements

*Deliver coaching, training, technical advice and support to the maintenance teams to (1) enable the teams to quickly and

efficiently return the equipment to full operating capability, and (2) to build team capability and increase performance

Coach Technicians on safety, technical and operational procedures, including risk analyses, to ensure high standards of

technical capability and performance

Assist Technicians to trouble-shoot

Perform the role of technical SME in at least one subject area

Educate the organisation in best practices for reliability-centred maintenance

Develop new KPIs; engage, train and motivate the teams to deliver against the new performance goals

*Lead, motivate and develop a small team to deliver high-quality reliability management services

Set individual performance objectives, action WPPs, manage performance.

Action the disciplinary cycle if necessary

Action development initiatives (observe; coach; train; counsel under-performers)#

Manage time and attendance while maintaining accurate SAP records

*Action the SA Environment, Health & Safety (EHS) procedures1 to ensure safety and compliance

Continuously action the SA EHS procedures

Analyse and mitigate EHS risks inherent in maintenance plans, tasks and projects

Apply the SA authorisation and isolation procedures, for example:

Monitor the protected areas and work areas and validate authorization or work permits; inform the departmental Supervisor

immediately of any accidents or unforeseen problems

Know and apply the SA housekeeping principles and procedures (5S) to maintain the work areas and storages in a safe,

efficient condition

Requirements

Essential qualifications, knowledge, experience and skills:

A degree in Engineering Mechanical or Electrical with minimum of 8 years of relevant experience,

Very deep technical knowledge.