General Superintendent - Area Maint.

1. JOB PURPOSE:

Ensure assigned plant maintenance KPIs are achieved, maintenance strategies/systems are implemented and required productivity & customer satisfaction improvement is accomplished to materialize Area Maintenance Objectives.

Lead multidisciplinary Maintenance Team working 24x7 in assigned area to meet Smelter Maintenance KPI.

2. KEY ACCOUNTABILITIES:

Risk Management

• Identify potential business risks (production/revenue, quality, cost, delivery, environment and health & hygiene) in advance, analyse them & take precautionary steps to reduce/curb the risks in the assigned area.

• Identify high-risk maintenance activities and develop action plan to mitigate the risk by developing engineering solutions and/or automation to keep the area personnel safe.

• Must be well versed with EMT/BCM policies and participate/contribute as & when required.

Planning

• Formulate Yearly Maintenance/Shut Down Plans in co-ordination with Operations, CMS & Planning and determine high level resource requirements for assigned area.

• Contribute to the development of long-term maintenance plans.

• Monitor key maintenance performance indicators to track performance and plan corrective/improvement actions.

• Discuss Weekly Maintenance Plans with Operation Team to confirm the equipment availability for maintenance.

Policies, Processes & Procedures

• Proposes & implement approved changes in maintenance policies & processes to improve.

• Develops maintenance procedures for safe, cost effective, efficient, quality and legislative compliant accomplishment of maintenance tasks.

• Ensures comprehensive understanding and adherence to work practices, schedules, policies, processes and procedures by all departmental personnel through effective team management. Implement corrective actions in case of variance.

• Communicate, co-ordinate the changes/updates and support the customer/suppliers/ contractors to ensure compliance to Policies, Processes & Procedures.

Budget and Financial Performance

• Contribute to assigned area budget preparation.

• Monitor, review and control actual expenditure to ensure all maintenance activities are managed within budget of the assigned area contributing to overall achievement of financial performance targets of Area Maintenance.

• Analyse, Work out & Implement corrective actions to address unfavourable financial variances.

• Right-source the maintenance jobs wherever it is beneficial to the company safeguarding core technologies/processes.

Maintenance Management

• Implements assigned area maintenance plans at optimum maintenance cost.

• Identify & manage enterprise/task risks related to assigned area maintenance activities and eliminate/mitigate the same.

• Ensures optimum utilization of the available resources & contracts in assigned area.

• Critically reviews assigned area asset performance and solves problems/improve performance using structured processes, reliability engineering, condition based maintenance and innovative approaches.

• Clearly lay down the guidelines to prioritise the jobs within assigned area.

• Responsible and accountable for addressing unplanned breakdown/corrective maintenance calls/notifications at optimum maintenance cost for all the equipment at assigned area.

• Manage Shift Maintenance team to:

  • Ensure all the calls/notifications received from customers are correctly recorded and appropriately addressed.

  • Control the area/situation where any incident/emergency has taken place and inform all the stakeholders.

  • Analyse the breakdowns and co-ordinate within department to address repetitive failure.

• Critically reviews asset performance and supports problem solving using structured processes.

Emergencies, Shutdowns, Call Outs & Major Maintenance Management

• Perform Shutdowns & Major Maintenance as planned to achieve the purpose within the planned budget & time frame.

• Closely co-ordinate and manage the Shutdown Activities for optimum cost & safe working.

• Provide guidelines & framework to team on callout decision making and emergency declaration.

• Always be ready (24x7) to actually arrive and manage the plant emergencies.

• Provide the possible support to areas working on shut downs within internal team during odd working hours.

Spares Inventory Management

• Monitor assigned area Spares, Tools and Consumables Inventory and implement corrective actions to maintain inventory within target ensuring availability of the required material of right quality at right time without impacting the equipment availability.

• Review and propose changes in Spares Specifications/Requirements/Suppliers/Levels.

• Propose the spares to be stocked for existing and new physical assets in the area of responsibility.

CAPEX & Other Projects’ Management

• Scientifically Assess and Propose the replacement/upgradation/refurbishment of area assets.

• Lead execution of approved Area Assets’ Replacement/Refurbishment/Upgradation/ Contracts/Other Assigned Projects to achieve the purpose within approved budget and planned time frame.

• Provide support to all Technical/Capex Project Teams in finalizing the design specifications & Scope of work, conducting factory acceptance testing, installation & commissioning and warranty management of assets in the assigned area.

Technical Guidance

• Provide sound multidisciplinary (Mechanical/Electrical/Instrumentation) technical guidance to team members in order to support in resolving complex issues related to equipment maintenance and reliability.

• Provide technical support to Operation Team as and when needed.

Collaboration and Networking

• Collaborate with customers to seek candid feedback and act on the same to achieve excellence in customer service.

• Manages the coordination with cross-functional teams such as the Operations, Planning, Capital Projects, Quality, Auditors, Suppliers and Contractors to enable effective flow of information and delivery of maintenance plans.

• Communicate & Co-ordinate with peers across the two sites.

People Management

• Practice visible presence in assigned area to keep the team focussed on jobs/quality/ delivery/safety/cost & motivated to perform in harsh environment.

• Ensure that all the maintenance activities are effectively supervised for safely, efficiency and cost effectiveness.

• Manages the team’s performance through involvement in recruitment, training and development activities in order to ensure high standards of performance and acceptable behaviours within the team.

• Set, Notify, Agree & Review performance measures/targets for each subordinate position in the department. Monitor, Provide Feedback & Record the performance of each subordinate against the performance measures/targets periodically. Train, Guide & Develop subordinates based on their actual performance to make them competent to render the services to the customers effectively & efficiently.

• Support UAE Nationals’ development & maximize Emiratisation of In Focus Positions.

Continuous Improvement

• Adopts innovative approaches/tools to identify improvement opportunities (related to man, machine, method, material, environment and measurement) / prioritise changes/improvement activities, facilitate the implementation & acceptance of change and contribute to sharing of best practices across the organisation in order to continuously improve productivity, reduce maintenance costs and enhance operational excellence.

• Evaluate & Introduce new / upcoming technologies for Automation, Robotics, Artificial Intelligence, Machine Learning, Data Analytics, etc. to improve the asset performance and productivity.

• Ensure participation of 100% personal under his control in business excellence initiatives such as Najah (Suggestion Scheme/Tamayaz/Improvement Projects), Kaizen, Asset Management, RCA Projects, 5S, etc. to improve safety performance, reduce cost and improve manpower productivity.

• Monitor and continuously improve the maintenance data integrity of assigned plant equipment.

Safety, Quality & Environment

• Highest priority must be given for the health, hygiene and safety of personal in dealing with all repair and maintenance activities.

• Contributes to the development of the assigned area specific safety, quality and environmental plans to embed safety as the highest priority of maintenance team.

• Ensures that the assigned area maintenance team adheres to all relevant health, safety, quality and environmental management policies, standards, procedures (ISO 45001:2018 (OH&S), ISO 9001:2015 (QM), ISO 14001:2015 (EM), IATF 16949:2016 (AQM)) and practices in order to guarantee employee safety, legislative compliance and a responsible environmental attitude.

• Maintain ISO 45001, IATF 16949, ISO 9001 & ISO 14001 documents and share the same with auditors to establish the compliance to the international standards & legal requirements.

• Ensure effective communication and implementation of continuously developed/updated aspects on Safety, Quality & Environment to achieve ZERO HARM to team members.

• Ensure appropriate maintenance of assigned plant equipment (Chlorine Plant, Dross Plant, Dust Collection Systems and Furnace Burners, FTP, GTC, etc.) to minimize the environmental impact and adhere to local regulatory requirements.

Related Assignments

• Performs other related duties or assignments as desired by Snr. Manager.