Engineering Manager, Head Of Engineering (Water, Power Generation, Renewable Energy, Processing Plants)

Main Responsibility

• Senior Manager responsible for electrical, control & instrumentation, mechanical engineering and civil engineering design matters, development, construction supervision, financial management and project management on various projects while providing assistance to the Project Manager and Chief Executive Officer. Accountable & responsible for scope definition and manages planning, resourcing and scheduling of all electrical, control & instrumentation and mechanical engineering related activities. Provide technical leadership, integrates the disciplines and resolves issues. Responsible for engineering systems and the delivery of all technical deliverables to achieve the project objectives within the specified timeframe and budget. To manage all external consultants providing electrical, control & instrumentation and mechanical engineering professional services during execution of various projects from inception to handover.

Equipment/Plant  Machinery Exposure & Technologies 

• Oil Refinery Plants, Minerals Processing Plants, Utility Systems (Gas, Compressed Air, Steam and Electrical Reticulation),  Abstractions Works, Water Treatment Works , Wastewater Treatment Works and Pump Stations Equipment: Cyclones, Centrifuges, Magnetic Separators, Ball Mills, Crushers, Coal Bunkers, Transfer Chutes, Boilers, Lifts,   Fuel Heating Systems,  Oil & Fuel Storage Tanks, Air Compressors, Blowers,   Bulk Water Pipelines, Reservoirs, Aeration System, Sand Filters, Settling Tanks with Rotating Bridges, Chlorine Dosing Systems, High Lift Pumps,  Pumps (positive displacement & centrifugal), Gearboxes, Heat Exchangers, Fans, Pressure vessels, Steel structures & bridges, Piping Systems &Valves, Filters & Strainers, Trash Racks, Mechanical Screens, HVAC, Agitators, Gravity thickeners, Screw feeders, Conveyor belts, Degritting Classifier Systems, Sluice Gates & Penstocks, Sludge bulk handling units, Mixers, Cranes, Medium Voltage Substations, Electric Motors, Variable Speed Drives Controllers, Electrical Distribution Boards, Transformers, Instrumentation and Control Systems 

Strategic Management & Leadership

• Advising on strategic delivery of the value chain of the primary or core business formulation of appropriate strategies to achieve growth, quality and efficiency targets of the clients
• Working with executive management and other peers for strategy development and execution planning
• Provide technical and professional advice to ensure strategic effectiveness of the clients  at the level of internal and external operating environments.
•  Proactively pursue sources of data and insight needed to complete analysis and ensure pace of progress and quality of analysis are maintained in line with the expectations of the Executive Managers and Board Of Directors
• Drive strategic delivery, generating critical insights and tailoring and delivering effective communications to drive change, through the proactive solicitation and use of information, judgment, problem-solving methodologies and sector knowledge
• Assess municipal infrastructure planning, development, implementation and operation & maintenance requirements of municipalities

People Management & Empowerment

• Assume responsibility for the engineering administrative function, directing Engineers, Technologists, Technicians and Draughtsman and other groups engaged in inter-related engineering responsibilities
• Evaluates and advises on the impact of long-range planning of new programs/strategies and regulatory action as those items affect the attraction, motivation, development and retention of the people resources of the organization
• Adopt and apply proven approach to strategic workforce planning to ensure that there is alignment between the people and business strategies needed both in the short term and long term
• Providing guidance to direct reports, typically comprising first-line managers and supervisors
• Ensure that training is planned, budgeted and implemented for resources assigned to the project.
• Directing and reviewing the engineering activities to ensure that work quality is satisfactory and appropriate technical personnel development programs are conducted

Engineering Services, Operations And Asset Management

• Provide support on specialized engineering services for oil refinery plants, minerals processing plants,  utilities systems ( gas, steam, electricity) ,water and sanitation engineering services
• Lead long & short-term capital improvement and preventative maintenance activities, working collaboratively with the other stakeholders
• Assist clients in establishment of engineering department priorities and goals; guide the preparation and maintenance of engineering department records, hydraulic models, plans, files, related materials, and assist in supervision and  management of the Geographic Information System
• Provide advisory services for efficient and cost effective bulk portable water production and distribution and bulk sewerage treatment and disposal, and associated infrastructure asset management and operations to ensure the achievement of service and quality standards.
• Assist clients in managing water service delivery infrastructure, championing water infrastructure planning, water abstraction ,water purification.
• Design new systems to solve complex engineering challenges and improve efficiency and enhance safety on water & sanitation projects
• Reviewing and approving work produced by sub-consultants, and engineers
• Monitor and oversee ground water quality, water treatment operations, and quality of the distribution system.
• Optimising appropriate design and cost-effectiveness of new projects as well as betterments/alterations/decommissioning of existing water infrastructure including risk management.
• Evaluating, editing and authorising all designs, reports, engineering drawings and specifications.
• Providing professional, technical advice as well as engineering support services  to other organizations.
• Keeping abreast with the latest developments in the fields of dam and water engineering and formulating new policies and standards to reflect the latest trends
• Coordinate with Procurement, Construction and Commissioning personnel early in the design effort to obtain their input and conduct any necessary reviews.
• Provides advice and support to clients on turnaround actions for utility services, water services activities, water treatment as well as wastewater treatment solutions and gives technical advice on energy (steam & electricity) management, process improvements,  water quality and physical asset management improvement strategies
• Conduct and lead the development of feasibility studies, technical reports and designs of water and sanitation infrastructure with special emphasis on regional water and sanitation schemes
• Lead projects incorporating Process, Civil, Hydraulic, Structural, Mechanical, Electrical and Control Instrumentation essential, including water treatment works, wastewater treatment works and pump stations
• Provide technical support in the development, review and the implementation of municipal sector master plans and regional water schemes
• Coordinate water works services, maintenance functions and other activities with other governmental units, utilities and private sector users.
• Conduct site evaluations and conditional assessments of process plants, manufacturing plants, cement plants, mining refineries, water treatment plants, bulk water transfer pump stations and wastewater treatment plants (from a civil, mechanical and electrical perspective).
• Coordinate quality audit verifications to ensure compliance with all relevant engineering standards and internal procedures for all design activities. Instigate corrective actions as required.
• Ensure engineering risk assessments and HAZOPs are carried out and all identified issues are addressed.
• Arrange ,facilitate  and contribute to design reviews as required during engineering design and construction phases.
• Ensure compliance with engineering design codes, standards, project and quality requirements.
•  Conceptualize, design development, detail design, contract documentation, specifications, drawings and other relevant project documentation.
• Produce feasibility reports, technical proposals, tender adjudication reports and close-out reports.
• Review and analyse technical drawings and specifications of engineering systems to ensure installation and operations conform to standards and customer requirements.

Programme & Project Management

• Development of the Project Execution Plan (PEP) together with the project leadership team (including procurement, project controls, construction, and commissioning), and allocate roles and responsibilities.
• Liaising with water and sanitation development partners and other stakeholders in the water sector for effective formulation, planning, coordination and implementation of projects and programs
• Providing input into the project monthly report with respect to design progress, cost and issues of concern and recommend changes if required to achieve overall objectives.
• Continuously liaising with other disciplines such as Geotechnical, Environmental, Structural, Electrical , Civil Engineering  engineers and  client management at key points throughout project to ensure that engineering deliverables are meeting client requirements
• Providing project/programme management during the implementation phase including supervision, contract administration and management of all aspects of the projects.
• Plan and implement research methodology and procedures to apply principles of engineering theory to projects
• Actively participate in and contribute to the technical aspects of projects in order to ensure that projects are delivered on time, within budget and to specification
• The overall co-ordination, programming of design and financial control of all the works included in the services
• Regularly review and appraise the structure of the engineering project team in terms of its ability to meet short- and long-term objectives, and institute appropriate changes.
• Undertake site support activities during construction and/or commissioning by inspecting construction worksfor quality and conformity to contract documentation

Financial Management

• Be responsible CAPEX and OPEX budgets in order to ensure cost effective utilization  and implementation of cost control measures to ensure optimum benefit and maximum risk exposure
• Provision of timely, accurate and adequate financial and other operational information for strategic decision making purposes; preparation of strategic plans, including advice on new strategies for achieving business objectives
• Provide assistance to clients in preparing five-year Capital Improvement Plan and budget; manage the acquisition of grants and assists with other external funding; implement and administer grants and external funding
• Initiate and defend rate reform, alternative financing methods, customer education, and customer service programs and activities.
• Estimate labour, material and construction costs and prepare specification and documentation to scope expectations

Corporate Governance Leadership

• Forge and maintain relations of trust with shareholders, partners and external authorities
• Formulate and review policies, supply agreements and the general conditions of water supply.
• Gather and provide information and provide advice on matters related to the business unit(s) supported and business and administration processes.
• Assist in proper planning for the acquisition of assets including the need to consider alternative strategies for the achievement of Government objectives
• Provide  and facilitate the consistent application of corporate governance framework and compliance across the entities.
• Assist in the regular review of governance processes including analyzing existing processes, recommending and implementing changes, documenting new processes and procedures to support compliance, continuous improvement and innovative best practice in governance.

Project Description

• Detailed Design Professional Engineering , Contract Administration and Construction Supervision of the Olifantspoort Water Scheme and Ebenezer Water Scheme Upgrades R 9,6 Billion
• Feasibility Study, Design and Construction of bulk water pipeline, construction supervision for Mhlana-Somopho Phase 3C Bulk Water Supply R 116,6 Million

• Provide leadership and strategic direction to power production operation, maintenance, engineering and project teams to enable Bio2watt to achieve set objectives
• Design and establish new processes which translates user requirements into system / sub-system functions within the company’s business processes.
• Implements technically innovative strategies and investigation techniques to support operations & engineering in an efficient and effective manner
• Evaluation of specifications and optimization of present operational systems in terms of effectiveness.
• Establish interfaces between suppliers , engineering & operations to provide process specifications as required to fully implement process improvements while developing and maintaining strong relationships with other internal and external interfaces and key strategic alliance partners.
• Ensure smooth daily power production operations and management which includes supervision, monitoring, coaching, developing, and performance management of employees to ensure a productive workforce in compliance with company policies, procedures and applicable employment agreements.
• Develop and implement asset management strategies in order to aiming to achieve assets reliability & productivity whilst minimizing breakdowns and extending equipment life span.
• Adheres and implements companies policies and procedures and ensures compliance to standards with respect to SHE/Quality/Engineering
• Review logs, datasheets, or reports to ensure adequate production levels and safe production environments or to identify abnormalities with power production equipment or processes
• Inspect biogas processes, equipment, and facilities for ways to maximize capacity and minimize operating costs
• Manage laboratory services to  ensure  consistency  in  blended  feedstocks,  biology of  the  AD  system,  quality  of  digestate  and  optimization  in  the  production  and  quality  of  the  gas. 
• Monitor operational financial expenditure vs budget and research ways  to  reduce  costs  while  maintaining gas  production  levels  and  gas  quality. 
• Remove waste  and  constraints  from  the  production  process  to  improve  efficiencies  and  enhance  productivity
• Prepare reports on biogas plant operations, status, maintenance, and other information.
• Evaluate power production or demand trends to identify opportunities for improved operations.
• Develop systems and processes that track and optimize productivity and standards, metrics and performance targets to ensure effective return on assets
• Prepare CAPEX plan for future projects according to company growth plans
• Develop target/business plan for the biogas plant in accordance with contractual and business needs.
• Ensure that all strategic, operational and manpower targets set for the biogas plant are achieved.
• Plans and controls technical resources in support of process and production improvement, to ensure cost reduction
• Ensure the highest level of safety standards and environmental compliance applies at all times by dealing with safety & environmental  matters  in accordance with procedures and regulations.
• Develop and implement training and development plans for staff in line with the technical and business needs
• Conduct periodic reviews of company policies and procedures to assure that they reflect current plant operating requirements
• Sets organizational priorities and allocates resources to meet plant and business objectives.
• Adapts plans and adjusts priorities as needed to meet the service and/or operational challenges of the plant.
• Identifies and resolves complex technical, operational and organizational problems.
• Monitors the operating status of plants by establishing and reporting relevant key business and operational performance indicators, and taking or assigning action to close performance gaps.
• Leads and directs the work of plant staff and coordinates with the business unit support group personnel as needed.
• Management of technical team through all project phases, from concept and project scoping and feasibility stage through detailed engineering design, procurement, project and construction management, commissioning management, handover and operational support
• Coordinate with Procurement, Construction and Commissioning personnel early in the design effort to obtain their input and conduct any necessary reviews
• Oversees staff to provide operations support functions, such as engineering and technical support, maintenance, work planning and execution, regulatory compliance, and administrative support.
• Ensures that a strong performance-driven culture is established and maintained at the plant with frequent engagement with employees at all levels. Guides employees and instil accountability to adhere to and actively support operations code of conduct, procedure usage, and other standards necessary to reduce errors and foster a culture of continuous improvement.

• To provide support to the COO and is responsible for supervising a team of mechanical engineering practitioners. 
• Provides leadership and assists in the resolution of technical matters related to the discipline for the projects. 
• Define and develop the plan to meet the project requirements and supports the team of mechanical practitioners to achieve the expected results in terms of quality, cost and schedule. 
• Main focusing on equipment design, maintenance, operation, performance optimization
• Ensures functional leadership with regards to project management, construction, maintenance engineering and technical expertise to mechanical engineering and engineering asset management.
• Industrial and municipal plants design of equipment control systems, piping systems and various equipment including pumps, valves, aerators, gearboxes, compressors, heat exchangers, mixers and motor selection.
• Utilize modern project management tools and techniques to execute turn-key projects which involves engineering, procurement and construction
• Participates in the development of P&ID’s, specifications, construction specifications, project schedules, project budgets, project staffing planning, and construction planning
• Prepare conceptual reports which will include preliminary designs and analyses, drawings, cost estimates, project schedules and project implementation plans
• Develop a thorough understanding of the project requirements as they relate to scope, cost and schedule
• Prepare a list of engineering deliverables and time based functions to facilitate the planning and control of the engineering budget
• Compiling contract baselines, tendering, adjudication, variations, progress monitoring, contract payments, quality control, keeping to the time and cost scales and liaising effectively with all stakeholders
• Perform, as required, the following: organize/plan jobs, support proposal and estimate activities, write/review specifications including design criteria, prepare/maintain schedules, develop/monitor estimates and manpower forecasts, assign work, work with project/client/field, material procurement, permit, and subcontract activities.
• Develop the mechanical work plan for insertion into the project specific execution plan
• Develop and maintain the project’s scope of work documentation and revise as required during the design evolution
• Manage and review the Engineering Work Packages (EWP) associated with all deliverables and time based functions to ensure that budgets and schedules are being met, and take corrective action if necessary
• Prepare and maintain a Manpower Forecast List (MFL) that supports the engineering schedule
• Supervision of construction site operations including supervision of mechanical installations, checking designs, drawings and ensuring that work is done as per the specifications as well as ensuring compliance quality standards. 
• Review and approve the mechanical and layout design criteria documents as well as mechanical engineering and design standards
• Review and approve mechanical technical deliverables (specifications, datasheets, drawings, etc.). 
• Facilitate coordinate, and attend design reviews, as applicable e.g. P&ID, HAZOP, Model, constructability reviews as well as FATs and SATs for Sub-contract supply.
• Assist in the preparation and development of project specific procedures
• Establish design tools, software, relevant codes and standards to be used on the projects
• Assign work tasks (via approved EWPs) to individuals and continuously monitor progress and quality
• Represent the mechanical practice in project engineering coordination meetings
• Schedule, coordinate and participate in mechanical design review
• Ensure coordination, between the mechanical team and other disciplines, of all activities being performed as the design evolves
• Serve as Supervising Lead, providing guidance/supervision to other staff and functions as mentor to less experienced engineers, technicians and trainees.
• Ensure that quality audits of engineering work are carried out in accordance with project procedures and the quality assurance plan
• Promote and maintain the application of ethical and professional practices in the execution of mechanical engineering work
• Ensure that all work designed, manufactured and supplied in the mechanical engineering discipline complies with the relevant sections of the Occupational Health and Safety Act (OHSA)
• Ensure that site related activities for the practice relating to mechanical equipment and systems are expedited in accordance with project and plant requirements relating to safety, quality and project delivery requirement

Project Description
Upgrading & refurbishment of Darvill Wastewater Treatment Plant from 55-120Ml/day- Pietermaritburg:
Civil Construction, supply of new equipment, install and commissioning.
Refurbish & replace mechanical, electrical and civil infrastructure to restore the functionality of the plant ±R650 Million Umgeni Water
Upgrading & refurbishment of Mpophomeni Wastewater Treatment Plant by additional 6Ml/day R160Million Umgeni Water

• Provide functional leadership with regards to management, engineering and technical expertise to engineering asset management, maintenance & reliability and production &operations business units
• Provides construction supervision services on the Mechanical & Electrical aspects of the project to ensure that the design documentation is safely and accurately implemented on site, and that the requirements of the construction contract are followed.
• Review the Contractors Quality Assurance Plans, Method Statements and Quality Control Procedure documents.
• Co-ordinate equipment inspections with the Client’s Quality Control team.
• Review the outputs of quality procedures and maintain records to be included in the project hand-over documentation.
• Be available to the Contractor to assist in interpreting designs, drawings and specifications. Liaise between the Contractor, Clients Representatives and the Office Base Design Team and assist with the general co-ordination of the design, installation and commissioning.
• Assists the Resident Engineer in reporting and monitoring progress of construction against the programme, and takes steps to ensure the programme is achieved including safety, financial recommendations, and quality control and design modifications.
• Evaluates, selects, and adapts construction management and control techniques, procedures, and criteria to suit job tasks, and devises and implements solutions to problems encountered.
• Development, implementation and improvement of a world class engineering, maintenance & operations strategy
• Conduct organizational business research by means of surveys and interviews , compile information and analyze statistics
• Coordinate the establishment, construction, commissioning and launch of multiple projects
• Responsible for the achievement of strategic and business objectives, covering construction completion, pre-commissioning, commissioning, safe start-up and performance testing stages
• Coordinating multi discipline technical bid clarifications and evaluations with vendors and contractors
• Undertake senior accountability role for staff management, with overall responsibility for a team of commissioning engineers, project managers, engineers, QA/QC inspectors, engineering sales & marketing representatives and production & operations managers
• Played a pivotal role in the fiscal management of the plant, with senior responsibility for fixed and variable cost management and implementation of capital projects
• Coach and manage engineering & operations team and build culture of pro-active business operations
• Provide technical risk management and corrective actions within various business units
• Provide technical scope negotiation and clarification services between various stakeholders and business partners
• Development and implementation of new technical and engineering procedures which to streamline operational targets
• Responsible for the overall administration of the new & refurbishment projects including the co-ordination of the work of the team, the programming of the execution of designs and the overall financial control of the projects.
• Supervise preparation of drawings for manufacture and installation or detailed checking of such for erection or installation fit.
• Detailed inspection, reviewing and checking of designs and drawings prior to approval processes
• Undertake duties falling under the Occupational Health and Safety Act, 1993 (Act No.85 of 1993) and the Construction Regulations in terms thereof, on behalf of the client,
• Convene and preside over regular meetings of the team and the client for purposes of administering the contract and planning the project including preparing and distributing agendas and minutes to all concerned.
• Co-ordinate the preparation of a budget for the client, together with assistance from other members of the team and update it at regular intervals as agreed with the client.
• Obtain the formal approval of the appropriate Government Departments or Public Authorities, including the making of such revisions as may be required as a result of decisions of such Departments or Authorities arising out of changes in policy,
• Prepare a construction and procurement plan and policy according to the client’s requirements with regard to types of contracts to be adopted, general and commercial conditions and the grouping of items and elements into various contracts.
• Making arrangements to provide the client, on completion of the works, with such record drawings as may be required for a proper record of the works as constructed and such manuals as may be required for the operation and maintenance of the relevant parts of the works.
• Evaluating results of project teams commissioning procedures and tests and witnessing final performance or acceptance tests on site.
• Process and certify all payment and valuation certificates and issue payment certificates for settlement.

Areas of responsibility Engineering Design & Asset Management
Project & Contract Management and Procurement & Finance

Equipment/Plant Machinery Exposure
Pumps (positive displacement & centrifugal), gearboxes, fans & blowers, compressors, centrifuge, pressure vessels, steel structures, welding technologies, bearings, Pipes &Valves, Filters & Strainers, bearings & seals, coupling systems & v-belts systems ,HVAC, Lubrication Systems, boilers, heat exchangers, agitators, sludge dewatering belt presses, screw feeders, conveyor belts, classifier, degritting systems, bio-filters, sluice gates, modules, Sludge bulk handling units, Aerators Reactor units, Mixers, cranes and transformers

Areas of Exposure

• Strategic Management, Financial Management, Supply Chain & Logistics, Human Capital Development, Engineering Asset Management, Projects & Contract Management and Corporate Governance for Public Sector.

Duties and responsibilities:

• Ensures functional leadership with a department with regards to engineering asset management, project & construction management, financial management and provide technical expertise with regards projects, contract management, maintenance & reliability engineering to support business operations within ERWAT.

Engineering Design & Asset Management

• Prepare mechanical design calculations, equipment selection and detailed designs for screening equipment, pump stations, settling tanks, boilers & steam plant, heat & ventilation systems, aeration systems, sludge handling equipment and disinfecting systems.
• Prepares mechanical equipment and package equipment specifications and data sheets, RFQ’s, technical bid summaries, and purchase recommendations
• Participates in the development of P&ID’s, specifications, construction specifications, project schedules, project budgets, project staffing planning, and construction planning
• Direct and coordinate the efforts of a multi-disciplinary team of in-house resources, sub-consultants, contractors, and suppliers.
• Develop engineering asset management strategies &plans, align to organizational strategy and implementation of programs
• Develop and re-engineer processes and procedures for life cycle engineering asset management
• Develop solutions, select and adapt relevant tools and technologies relevant to international engineering asset management standards to improve OEE (Overall Equipment Effectiveness). 
• Implementation & continuous improvement of asset management strategies and policies as per Municipal Infrastructure Asset Management Guidelines and Public Available Standards for Asset Management (PAS 55) for readiness of ISO 55000 implementation.
• Propose new design modifications and conduct impact analysis on plant performance and ensured that changes complies to the desired standards : SANS, ASME, BS and EN 
• Development and implementation of RBI (Risk Based Inspection) approach for asset integrity management, RCM (Reliability Centered Maintenance) strategies and RCFA (Root Cause Failure Analysis) methodologies to prolong equipment life-span and maximize performance of engineering assets.
• Ensure that the Engineering Contracts (EC) aligns with design, operating and maintenance philosophy
• Enforce compliance to SHE standards to ensure targeted levels of plant safety and environment 
• Manage and conduct technical analysis of operational performance, maintenance and diagnostic data to identify and communicate abnormal conditions, assist in root cause investigations, review plant data and performs trend analyses to detect present and potential system/equipment problems ,recommends effective corrective actions and identify potential cost savings based analyses of plant O&M performance data and identification of improvement opportunities.

Project, Construction And Contract Managment

• Ensures the achievement of strategic and business objectives, covering construction completion, pre-commissioning, commissioning, safe start-up and performance testing stages during projects
• Management of technical team through all project phases, from concept and project scoping and feasibility stage through detailed engineering design, procurement, project and construction management, commissioning management, handover and operational support
• Identify needs, plan, manage and execute capital & renewal projects within set time limits and acceptable quality and cost parameters
• Conduct feasibility options and evaluate means of purchasing or leasing of plant, equipment, material, systems, land or building during the projects conceptual stages
• Contribute to the development of the Project Execution Plan (PEP) together with the project leadership team (including procurement, project controls, construction, and commissioning), and allocate roles and responsibilities. 
• Ensure the scope of work is developed and an effective change management system is in place.
• Develop the engineering budget to meet the scope and execution plan for multiple projects.
• Develop the engineering work packages (EWPs) for all deliverables and time-based functions.
• Develop an achievable engineering schedule to meet project requirements using the EWPs.
• Work with the Practice Leads to ensure adequate resources are mobilized to the project.
• Provide input into the project monthly report with respect to design progress, cost and issues of concern and recommend changes if required to achieve overall objectives.
• Coordinate with Procurement, Construction and Commissioning personnel early in the design effort to obtain their input and conduct any necessary reviews.
• Make contact with client management at key points throughout project to ensure that engineering deliverables are meeting client requirements.
• Regularly review and appraise the structure of the engineering project team in terms of its ability to meet short- and long-term objectives, and institute appropriate changes.
• Keep abreast of new technologies and developments within engineering, built & environment industry
• Assume responsibility for the engineering administrative function, directing Area Engineers, Discipline Engineers and other groups engaged in inter-related engineering responsibilities. 
• Raise safety awareness and ensure the design for safety principles are applied to the project and undertake duties falling under the Occupational Health and Safety Act, 1993 (Act No.85 of 1993) and the Construction Regulations in terms thereof, on behalf of the client.
• Ensure engineering risk assessments and HAZOPs are carried out and all identified issues are addressed.
• Arrange and facilitate design reviews and participate as required in engineering, management and construction reviews.
• Coordinate quality audit verifications to ensure compliance with all relevant engineering standards and internal procedures for all design activities. Instigate corrective actions as required.
• Direct and review the engineering activities to ensure that work quality is satisfactory and implement quality management system or quality assurance services, over and above construction monitoring services
• Plans and establishes engineering schedules and follows up performance against estimates, this includes formulation of project scope utilizing projects scheduling tools and techniques to schedule tasks, deadlines and milestones for all stakeholders and resources, this includes identification of financial requirements in the management plan

Finance, Procurement & General Management

• Manage an operational budget (OPEX) of ± R56 million (annually), capital budget (CAPEX) of ± R 800million (annually) and generate an income of ± R25 million (annually on external business)
• Take overall responsibility for cost management, working in line with strict, predefined budgetary constraints related to variable and fixed costs as well as capital expenditure
• Studying capital and operating expenditure trends and forecasts received from internal departments and preparing estimates with due consideration to internal and external funding requirements and limitations
• Initiates cost reduction proposals from other sources, compiles appropriate information, makes recommendations for action, and checks on results obtained 
• Manage procurement compliance within area of responsibility and participate on the supply chain management processes such as formulation of tender specifications, tender evaluation and tender adjudication to ensure compliance with Public Financial Management Acts (PFMA) and Municipal Financial Management Act (MFMA).
• Liaise with various departments such as Supply Chain, Legal and Risk Management Office and others within an organization to enable excellent production & operations 
• Ensure that training is planned, budgeted and implemented for personnel within a department
• Implement corrective measures and give feedback to staff with regards to statistical information pertaining to staff attendance/absenteeism, overtime, lost time due to accidents and /or incidents, down time and proposing specific remedial measures aimed improving productivity and reducing personnel related costs 
• Coach, train and motivate personnel to ensure sound employee performance including recruitment, promotion and personal development of individuals
• Presentation of technical scope, negotiation and clarification between various stakeholders and business partners

Statutory/ OHS Act appointments:
Supervisor as per Section 8(2) (i)
Assistant to Competent person –GMR 2(7)

Maintenance Manager
May 2009 - July 2009

Areas of responsibility
Wastewater Treatment plant, portable water reservoirs, water & wastewater pump stations and internal & external projects

Equipment/Plant Machinery Exposure
Pumps (positive displacement & centrifugal), gearboxes, fans & blowers, compressors, centrifuge, welding technologies, bearings, Pipes &Valves, Filters & Strainers, bearings & seals, coupling systems & v-belts systems ,HVAC, Lubrication Systems, boilers, heat exchangers, agitators, sludge dewatering filter belt presses, screw feeders, conveyor belts, classifier, degritting systems, bio-filters, sluice gates, modules, Sludge bulk handling units, Aerators Reactor units, Mixers, cranes and transformers

Duties and Responsibilities

• Managing and control all Maintenance & Mechanical engineering and project engineering-related functions in order to maximize equipment availability at the lowest cost and according to ensure maximum plant efficiency is achieved and clients.
• Provide technical leadership and program coordination in plant performance analysis and testing, assist staff in monitoring and improving unit efficiencies which includes managing and training of engineering teams and coordinates activities of engineering department to develop and improve systems and services.
• Establish engineering standards and policies for installation, modification, quality control, testing, operating procedure, inspection, and maintenance of equipment, according to engineering principles and safety regulations 
• Provides engineering and technical expertise and guidance for plant system/equipment repairs, modifications, and replacement/upgrades.
• Plans, oversees, and coordinates activities concerned with development, design, construction, modification, and maintenance of equipment, machinery and facilities
• Ensure effectiveness of various maintenance strategies such preventative, corrective, planned maintenance and condition monitoring
• Application of root cause analysis tools such as 5 Why’s & Ishikawa (Fish-bone) methods to determine the root cause of the problem and sets out containment action for short term and permanent action for the long term on assets
• Implement effective Reliability Engineering systems to ensure the improvement of MTBF and decrease the MTTR, to enhance the throughput of the process and contribution improvement of the OEE 
• Monitor and prioritize ad-hoc maintenance of equipment on a daily basis to minimize downtime using reliability-centered maintenance, utilizing CMMS (Computerized Maintenance Management System).
• Co-ordinate routine maintenance, including major shutdowns with internal and external clients and ensure the timeous allocation of manpower, funding and other resources to minimize downtime during maintenance period.
• Ensure adherence to Engineering Specification and quality standards, the OHS Act and legislative requirements
• Consult with Reliability, Mechanical and Electrical engineers on maintenance improvement and promote quality management practices and processes.
• Outsourcing of emergency repairs and maintenance of equipment by means of the tendering and procurement processes
• Keeping abreast of technical developments by providing continuous inputs on improvement and co-ordinate, plan and manage major repairs and upgrades to the plants as required to improve OEE (Overall Equipment Effectiveness)
• Manage and control expenditure and income according to approved budgets and report variances including CAPEX
• Continuously analyze and interpret maintenance information to optimize equipment utilization and maintenance at the lowest cost including maintaining of predictive and preventative maintenance programs.
• Update the assets register as required and co-ordinate the condemnation of assets and equipment, this includes ensuring that all code 29 equipment are tested and inspected according to the safety standards and keep the register of all equipment
• Liaise with external customers in terms of maintenance contracts to ensure compliance with technical standards.
• Investigate and report on the economic and technical availability for the replacement of equipment, and manage the implementation of new technology with minimum downtime and according to project schedules and
• Monitor the performance of employees under my supervision to ensure a high level of productivity through training, coaching and motivation. 
• Ensuring technical developments within employees that I manage and ensure they are treated fairly and in consistent manner in line with company policy and procedures

Plant Machinery for Machining Foundry; Rubber plant and Tool making 

Gas Boilers, Pumps, Pump testing equipment , Extractor fans & units, Compressors & pressure vessels ,Furnaces, Sand reclamation shake-out, Floor moulding loop, Fast loop mixer, wheelabrator, fettling bay; Chemical treatment stations;CNC’s(Lathes, bores, slotters ,milling and grinders) ; Sterllite plant
Rubber moulding presses, Autoclaves, Rubber intermixers ,Mills & sand blasting machines; Band saw’s, drilling machines , welding machines, Spray booth-bay’s and assembling equipment , Cranes, Bulk handling systems (Conveyor belts and chains),Fork trucks, Refrigeration, Air-con & ventilation systems, Cooling towers, Transformers and general electricity distribution

• Daily maintenance management duties within Engineering department which includes plant maintenance (predictive, preventative and reactive) equipment to ensure maximum availability and utilization for production
• Planning and executing programmed maintenance items and monitoring routine maintenance/backlog in order to ensure optimum plant performance
• Participate in effective management of the operations ensuring that product quantity and quality satisfy requirements and standards (Lean Manufacturing Practices)
• Liaise with production and support services to ensure plant machinery availability
• Analyze incidents or problems encountered and implement corrective action on daily basis
• Implementation of systems and procedures to ensure high plant, equipment reliability and quick resolution of breakdowns
• Improve reliability of the equipment in accordance with the request of internal customers
• Coordination of team activities and development of team and members
• Implementation of all statutory, legal, safety policies , procedures and Safety of plant equipment and
• personnel in compliance with OSH Act i.e. safety systems, occupational health, environment and quality and ensuring safety and legal documentation updates are conducted
• Managing the implementation of mechanical maintenance strategy at plant level and manage shutdown
• related activities
• Ensuring safe keeping of technical documentation provided by equipment and service suppliers
• Assist in preparation and management of budget cost and CAPEX
• Planning, organizing and controlling of projects
• Preparing and presenting technical reports

• Provides process and technical support to the machine crews on shift in order to maintain and optimize asset process stability and develop crew’s process knowledge to achieve safety, quality and productivity targets.
• Promote and participant in mill loss control management by utilizing Modern Safety Management Principles, World Class Manufacturing Principles and compliance with all local, state regulations
• Ensure compliance to all departmental and plant safety rules and regulations. All non-conformances should be dealt with immediately all unresolved issues must be raised with Asset Leader. Carry out continual development of process optimization to ensure safety.
• Ensure all quality issues are reported and logged on the appropriate documentation.
• Ensure all good run settings are determined using the center-lining process and are then documented and controlled. Any changes to process settings must be documented in the center-lining control charts. Maintain a “run to target” philosophy at all times.
• Continuous monitoring of quality charts results and coordinating of relevant corrective actions.
• Assist in providing answers to customer quality complaints and providing action plans to prevent these from re-occurring.
• Enforce and ensure line clearance procedure is adhered to at all times.
• Continual process optimization in order to achieve the correct rate of operation, waste, delay and volume without compromising safety and quality. Investigate and document all reasons for waste and delay during the shift in the shift log book, communicate any outstanding items with recommended action plans.
• Control and continuously optimize all changeovers, ensuring they are performed using good run settings and best practices at all times
• Maintain 5S housekeeping principles in the department at all times, including all equipment and surrounds. Ensure all unused items are removed from the operating area and stored correctly.
• Ensure the work area is clean and tidy at shift change, handover with the oncoming process technician giving detailed information of machine status
• Identify areas of development required for team members to improve individual and team performance.
• Ensure that all departmental guidelines are adhered to by the team. Inform the Asset Leader of any non-conformances immediately this includes performance and disciplinary measures
• Manage the inspection and replacing of all wearing parts in accordance with the relevant PM schedules.
• Assisting with the planning and set up of the machine for all product and process trials.
• Provide technical information to the maintenance teams detailing work requests for planned and reactive maintenance.
• Development of the team’s process knowledge on an ongoing basis through one on one coaching and employee assessments.
• Ensuring the continuous optimization of change-overs on machines.
• Adhere and implement best practices on the machine.

Plant Machinery Generators, alternators, air compressors , fans, blowers, steam boilers, heat exchangers (heaters and coolers), Propulsion engine and associated systems, pumps (centrifugal, mono, gear, vane, screw and vane),purifiers, refrigeration and air conditioning plant, sewage plant, fresh water generation plant, 2-stroke engines, 4-stroke engines and associated control systems.

Duties and responsibilities:

• Perform all hands-on duties of plant maintenance of main machinery (Carry-out major maintenance of mechanical engineering systems, machinery and control systems
• Assist in the development and improvement of plant operations according to required standards and specifications 
• Evaluate plant availability and failures then develop corrective action plans
• Delegate duties to artisans, provide guidance and supervise
• Member of problem solving technical team within plant
• Participate on plant development projects 
• Check plant performance by logging down operating data parameters, prepare plant performance analysis report ,do visual plant inspection and prepare formal overall plant reports
• Manage consumption of fuel, lubricating oil, waste oil, fresh water within storage tanks and machinery then prepare formal reports
• Operate pumping systems and associated control systems
• Carry-out boiler water tests, cooling water tests and lubricating oil tests, then apply water treatment according to findings from tests
• Perform specific tasks on controlling of stores and stores management system

• Studying blueprints, sketches, drawings, manuals, specifications, or sample part to determine dimensions and tolerances of finished parts, sequence of operations, and setup requirements.
• Measures, marks, and scribes dimensions and reference points on material or work-piece as guides for subsequent machining as necessary.
• Aligns, and secures holding fixtures, cutting tools, attachments, accessories, and materials on machines.
• Starts and observes machine operation to detect malfunctions or out-of-tolerance machining, and adjusts machine controls or control media as required.
• Verifies conformance of finished work-piece to specifications using measuring and inspection tools as necessary.
• Machining of different features on bearings in compliance with Lean Manufacturing methods
• Consult with engineers, production personnel, programmers, or others to resolve machining or assembly problems.
• Sets up and operates machine on trial run to verify accuracy of machine settings or programmed control data.
• Performs routine maintenance tasks on machines as required.
• Responsible for maintaining a well-organized area in compliance with all company policies and guidelines.
• Conduct production quality checks & auditing and packaging 
• Continue to grow lean knowledge and use the tools to identify and assist with continuous improvement.
• Comply with safety regulations and maintain clean and orderly work areas.