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Maintenance Manager - Cement Plant

FL Smidth Private Limited
10 - 20 yrs
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At par with market standard, best in the Inductry Openings: 1 Posted 10 days ago Job Applicants: 1221 Job Views: 1500+

Job Description

 
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    Job Summary
    Responsible for the implementation of preventive maintenance system & maintenance strategies for the Plant. Implement and develop the Reliability Maintenance processes and mind set. Ensure optimum equipment availability and performance of Plant equipment short, medium, and long term, at minimum cost. Facilitate communication with Maintenance Team, to ensure that best practice standards and specifications are maintained and improved in all manufacturing activities including design, procurement, maintenance, and operation.

    Duties and Responsibilities

    Safety

    Ensure compliance with the relevant statutory legislation and internal company Safety, Health & Environmental standards
    Communicate clearly on information relating to potentially dangerous situations and get confirmation that they are correctly understood.
    Development & availability of HIRAC, SOP's and corrective action plan (COP) for the maintenance activity
    Ensuring the permit to work system and any other safety system (Hot Work, Confined Space, Work at Height, lifting, slinging and rigging, Braking Ground etc.) are strictly adhered to
    Assess risks, carry out Risk Analysis and plan corrective actions as and when required
    Ensure good working conditions and safety standards are maintained within all areas of mechanical operations Comply with all relevant statutory legislation and Health and Environmental Standards.

    Maintenance Management

    Formulate maintenance strategy considering the best industry practices in RCM philosophy on maintenance.
    Ensure the best optimization of maintenance operations relevant to the availability of equipment and maintenance resources
    Achieve plant reliability/availability and maintenance KPI's world class practices and contractual obligation.
    Contribute to Plant global KPI achievements
    Plan for the allocation of resources for the weekly/monthly & annual maintenance schedules.
    Ensure proper tools are available and used for performing the maintenance activities
    Provide necessary inputs to Reliability Centered Maintenance for critically analyzing the history, failure trends, condition monitoring reports for optimizing the maintenance activities
    Record maintenance parameters like MTTR (Mean Time To Repair), MTBF, equipment performance, etc., and continually improve upon them
    Liaise between functions to ensure consistency, coordination, and best practice to eliminate losses from poor practices, expedite learning, etc.
    Conduct Plant visits by walking through plant & record observation of visible abnormalities if any and advise the concerned people.
    Plan and Schedule and prepare major shutdowns ensuring coordination with all departments
    Conduct & participate in Root Cause Failure Analysis as per identified threshold criteria and validate recommendation & monitor implementation of solutions.
    Implement & Maintain CMMS (Maximo/PI/CBM) to maximize their potential to the organization.
    Proactively supporting individual functions, i.e. design, purchasing, maintenance, stores and operations to ensure maintenance practices are adopted and implemented.

    Maintenance Optimization

    Ensure reliability centered maintenance is in place and maintenance staff are trained in reliability centered maintenance.
    Drive improvements in site availability and performance, including costs, by the implementation of maintenance best practices across the whole site
    Benchmark maintenance activities in terms of the time / resource required with the best industry norms and continually improve reliability across all areas
    Team Management
    Implement daily, weekly, monthly plant operation practices & cross functional coordination.
    Define the mission & objectives of his staff and conduct PDR sessions
    Development of maintenance staff by developing IDP's, defining skill gaps, and where necessary, providing training in activities that support production improvement and coaching.
    Develop succession plan for maintenance department & ensure successors for key positions.
    Promote quality of work and motivates his staff.
    Prepare the plant Organization & People review, including the Plant Team Assessment.

    Client Relation

    Interact with Client when required with respect to the status of the planned maintenance activities and further plans including maintenance optimization plans
    Take up issues that would affect the equipment availability / performance with the client
    Discuss with Client and look for opportunities for carrying out OBM
    Documentation of all plans / reports / maintenance history / decisions, reports, communication with vendors / client, etc.,
    Report equipment availability / reliability dashboard including the maintenance activities planned / carried out

    Team Management

    Define the mission & objectives of his staff and conduct PDR sessions
    Development of production staff by developing IDP's, defining skill gaps, and where necessary, providing training in activities that support production improvement and coaching.
    Develop succession plan for production department & ensure successors for key positions.
    Promote quality of work and motivates his staff.
    Implement daily, weekly, monthly plant operation practices & cross functional coordination.
    Prepare the plant Organization & People review, including the Plant Team Assessment.

    Performance Criteria

    Safety Performance
    Frequency and severity rate of accidents of maintenance personnel and contractors.
    Financial performance:
    Maintenance cost index.
    Maintenance budget compliance.
    Technical performance:
    Reliability, especially raw mills, burning lines and cement mills, as well as equipment failure rate.
    Number of stoppages for incident (NSFI) and mean time between failures (MTBF).

Salary: At par with market standard, best in the Inductry

Industry: Construction / Engineering / Cement / Metals

Functional Area: Production , Manufacturing , Maintenance

Role Category:Production/Manufacturing/Maintenance

Role:Project Manager-Production/Manufacturing/Maintenance

Employment Type: Permanent Job, Full Time

Keyskills

Desired Candidate Profile

    Education

    BSc, MSc Engineering Degree Mechanical, Industrial or Electrical with MBA will be an added advantage

    Knowledge and specific Experience

    Competent person OSHA Act & Regulations
    Knowledge Cement Manufacturing Process
    Knowledge of Environmental compliance
    Reliability Centered Maintenance mastery
    Grinding Plant Equipment Technology mastery
    Knowledge Electrical Technology
    Demonstrate the ability of Project Management
    Finance & Cost mastery
    Shutdown management mastery

    Technical Skills

    Cement plant operation & Maintenance, Budgeting, Materials Management.
    Root Cause Analysis, Maintenance Management Systems NEBOSH

    Interpersonal & Management Skills

    Fluency in English and Arabic
    Ability to deal with pressure & a stressful work environment.
    Leadership & Employee development
    Employee Engagement Ability to communicate
    Presentation Skills,

Education-

UG: B.Tech/B.E. - Any Specialization, Electrical, Mechanical, Diploma - Any Specialization, Electrical, Mechanical, B.Sc - Chemistry, Any Specialization

Company Profile:

FL Smidth Private Limited

FLSmidth is an international engineering company with an annual turnover of EUR 2.6bn. We are the world’s leading supplier of plants, machinery, services and spare parts to the cement and minerals industry. To maintain our market leading position, we invest massively in technological innovation, R & D and training of our 10,800 employees worldwide. Visit www.flsmidth.com for further information on our business and services.
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