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:

2.1 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

1. Perform detailed analysis to inform recommendations on Reliability Projects; calculate the payback period and ROI.
2. Prepare data and reports to inform management decision-making
3. Facilitate the meetings to determine priorities and select reliability projects

2.2 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

2.3 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

2.4 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

2.5 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

2.6 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

2.7 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

3.8 Action the SA Environment, Health & Safety (EHS) procedures 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:

1. 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.

Deep knowledge of the Departmental business, including the production processes, production economics, organisational structure and decision-making processes, business needs and constraints, budget, planning, legal and public relations constraints. This knowledge is critical as it enables the Engineer to design and deliver solutions that work for the business and deliver superior ROI