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Job description:
PURPOSE
The Plant Maintenance Manager supports the Engineering Manager in overseeing the maintenance, planning, reliability, and optimisation of equipment and processes in a large processing plant. This role ensures that all engineering activities align with safety, environmental, and operational standards while optimising equipment performance and reducing downtime through effective planning, shutdown planning, supplier engagement, and spare parts management.
KEY RESPONSIBILITIES
The incumbent will be required to adhere to all relevant requirements, policies, procedures and legal regulations pertaining to health, safety, environment and quality, as well as finance, human resources, and any other regulations as required by the company and relevant to the level of the role and responsibilities of the function. Plan, execute, and monitor preventive and corrective maintenance programs. Ensure proper installation, commissioning, and troubleshooting of plant equipment. Support reliability engineering initiatives to reduce downtime and optimise asset performance. Coordinate with the procurement and inventory teams to ensure the availability of critical spare parts. Implement condition monitoring and predictive maintenance strategies.
Safety:
- Enforce strict adherence to safety protocols and regulatory compliance standards within the maintenance team.
- Conduct regular safety meetings, audits, and inspections to ensure a safe working environment for all maintenance personnel.
- Creating and maintaining a safe and healthy work environment for a large workforce
- Ensure full implementation of SHE systems by setting clear expectations and leading by example
- Understanding and monitoring all high-risk work activities, ensuring critical controls are verified and effective
- Managing emergency situations and escalating as required
- Ensuring the Team’s full compliance with relevant company policy and regulatory requirements
- Addressing issues of non-compliance in an effective and timely manner
Leading and developing an effective team:
- Lead and motivate a team of superintendents ensuring a productive, efficient and safety focused work environment.
- Conduct regular team meetings, provide training, and facilitate professional development opportunities for staff.
- Coaching and providing timely and constructive feedback to the team
- Ensuring every key role has a succession plan
- Assigning development tasks consistent with agreed to career development paths
- Celebrating success and address instances of underperformance
Work Management:
- Maintain an optimal inventory of critical spare parts to minimize downtime. Work closely with the warehouse and procurement teams to manage stock levels and reorder points. Implement cost-effective spare parts management strategies, reducing excess inventory while ensuring availability. Evaluate spare parts usage and recommend alternatives or improvements for cost savings.
- Lead the planning and execution of plant shutdowns, ensuring efficient use of time and resources in line with AMP requirements. Develop detailed shutdown schedules, work scopes, and resource allocation plans. Coordinate with operations, safety, and project teams to align shutdown activities with production goals. Conduct post-shutdown reviews to identify areas for improvement in future shutdowns.
- Utilise computerised maintenance management systems (CMMS) for efficient and effective work management
- Monitoring and optimize performance across teams by field observation and performance gap analysis to elevate all teams to consistent performance standards;
- Engaging and collaborating with peer superintendents and other support functions to identify overarching risks and bottlenecks
- Review, refine and implement comprehensive Asset Management Plans (AMP) supporting preventive maintenance programs for the processing plant.
Supplier and contractor engagement:
- Work with suppliers, vendors, and contractors to ensure the timely procurement and delivery of critical components. Review service contracts and evaluate vendor performance for quality and cost-effectiveness. Develop strong relationships with OEMs (Original Equipment Manufacturers) and service providers. Ensure contractor compliance with safety and operational standards during maintenance and shutdown activities.
Equipment Performance Optimisation:
- Work closely with process engineers and production teams to optimise plant performance, contributing to overall operational efficiency.
- Implement reliability-cantered maintenance strategies to enhance the lifespan and performance of the crushers and conveyors.
- Implement Asset Management Plans
Data Analysis and Reporting:
- Utilise data analytics tools to track key performance indicators (KPIs) related to plant maintenance.
- Generate regular reports for senior management, highlighting maintenance trends, costs, and areas for improvement.
Financial Management:
- Assist in managing capital projects related to plant upgrades and process improvements. Monitor and control engineering budgets, costs, and resources.
- Drive innovation and implementation of new technologies to enhance efficiency and productivity. Collaborate with the finance department to develop and manage the maintenance budget, ensuring cost-effective practices and adherence to financial targets
- Developing an awareness of maintenance costs within the crews, focusing on the reduction of waste.
- Contributing to the development and monitoring of the departmental budget.
QUALIFICATIONS:
- Bachelor’s or Diploma in mechanical or electrical engineering,
- Professional Registered member of the EIZ and ERB.
- In-depth knowledge of plant maintenance best practices, including preventive and corrective maintenance strategies.
- Strong understanding of safety regulations and compliance standards in processing operations.
- Excellent communication and interpersonal skills.
- Proficient in the use of computerised maintenance management systems (CMMS) and data analysis tools
- Strong leadership and team management skills to lead and motivate a team of maintenance professionals
- Proficient in developing and managing maintenance budgets, controlling costs and setting up life cycle costing models.
- Effective communication skills for coordinating with various stakeholders, including maintenance teams, engineers, and management.
- The ability to analyse complex technical problems and develop practical solutions.
- Must have a current driver’s license.
- All academic qualifications and results must be verified by the Zambia Qualifications Authority (ZAQA).
EXPERIENCE
- Minimum 15 years maintenance experience in the processing/mining, with 7 years in senior leadership roles. At least 3 years working as a manager with a proven track record.
BEHAVIOURAL TRAITS
- Proven conflict resolution skills; and
- Previous experience working in a fast paced, cross cultural environment
- Past experience as an effective, visible and approachable leader, with the ability to work with a diverse group of people
OPERATIONAL REQUIREMENTS
- Extended hours may be required based on operational demands
- Exposure to dust, heat and noise
- Advance PC skills and database experience
- An understanding of relevant legislation, policies, equipment and procedures.
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