Website Samancor Chrome
Samancor Chrome’s history goes back as far as 1975, when it was established as a result of a merger between SA Manganese Ltd and Amcor Ltd. SA Manganese was formed in 1926 to mine manganese ore in the Northern Cape. Amcor was established in 1937 to exploit mineral deposits for the steel industry a… read morend to process those minerals into ferroalloys. Samancor was listed on the Johannesburg Stock Exchange until 1998 when the minority shareholders were bought out by the then majority shareholders, Billiton and Anglo American. This resulted in the delisting of the company and shareholding of 60% African Metals Ltd (a BHPB Company) and 40% Anglo South Africa Capital (Proprietary) Ltd (an Anglo American company). Samancor then consisted of chrome and manganese operations and stainless steel investments with marketing and distribution arrangements via structures held wholly and indirectly by BHPB and Anglo American. Towards the end of 2004, bids were invited for the purchase of Samancor Chrome. The successful bidder, the Kermas Group, effectively took over the operations from 1 June 2005. Samancor Chrome is currently owned by Samancor Chrome Holdings Proprietary Limited, which is in turn held by Terris Chrome Limited (which holds in excess of 70%), a minority shareholder and various Black Economic Empowerment Shareholders. What we do South Africa currently supplies in excess of 30% of world wide ferrochrome demand. This position can be ascribed to the following factors: The Bushveld Igneous Complex, which contains nearly 70% of the estimated world reserves of chromite; The development, in the early sixties, of the AOD process which facilitated the introduction of South African charge chrome into the stainless steel industry; and Historically cheap power, driven by the existence of extensive steam coal reserves. Over 70% of Samancor Chrome’s chrome ore output is consumed in the production of ferrochrome in South Africa. The remainder of the ore is exported. Some 85% of chrome alloy production is exported to stainless steel producers across the globe. Stainless steel, a steel alloy, typically contains 18% chrome and 8% nickel. The chrome content in stainless steel gives it its luster, shiny appearance and resistance to corrosion. Our outputs include the chrome ore extracted by our mines and chrome alloys produced by our plants. Samancor Chrome's four fully integrated and self-reliant chrome alloy plants have a combined annual production capacity of more than 1.2 million tons of alloy, including charge chrome and ferrosilicon chrome. The company’s total chromite resources exceed 650 million tons and are expected to support current mining activity for well over 100 years at the current rate of extraction. Some ores and concentrates are exported, but main allotments are destined for conversion into ferrochrome at the alloy plants. Who we are Samancor Chrome’s core business is the mining and smelting of chrome ore. With an annual capacity of some 1.2 million tons of ferrochrome and chromite ore, Samancor Chrome is one of the largest integrated ferrochrome producers in the world. We produce ferrochrome, which is used in different areas of the stainless steel smelting process. Samancor Chrome is a private company. The previous shareholders, BHP Billiton (60% ownership) and Anglo American (40% ownership), sold the company to the Kermas Group in June 2005 after evaluating several offers to arrive at the option promising the most prosperous future for the company and the best value for shareholders. Samancor Chrome is currently owned by Samancor Chrome Holdings Proprietary Limited, which is, in turn, held by Terris Chrome Limited (which holds an excess of 70%), a minority shareholder, and various Black Economic Empowerment Shareholders. The company's corporate office is based in Sandton, Johannesburg. Four ferrochrome plants and two chrome ore mining complexes operate as separate business units in different locations in South Africa: Western Chrome Mines in the Rustenburg area in the North West Province. Eastern Chrome Mines near the Lydenburg /Steelpoort area of the Limpopo Province. TC Smelter in the Rustenburg area in the North West Province. Ferrometals near eMalahleni, Mpumalanga Province. Middelburg Ferrochrome near Middelburg, Mpumalanga Province. Tubatse Ferrochrome in the Lydenburg / Steelpoort area of the Limpopo Province. Where we’re going Samancor Chrome is the second largest ferrochrome producer in the world, producing, subject to market conditions, in excess of 1 million metric tons (Mt) of charge chrome per annum. In addition, Samancor Chrome sells more than 2 Mt of chrome ore per annum on the local and export market. The potential of the company’s mineral resources, its dynamic leadership, and the technological innovation, infrastructure and knowledge capital developed over the years, combine to depict a very positive future for Samancor Chrome. Samancor Chrome continues to develop and implement best practices in all areas of operation. 1st Floor, Block B, Cullinan Place, Cullinan Close (off Rivonia Road), Morningside, Sandton, South Africa, 2196.
PURPOSE OF THE JOB:
To continuously improve the Asset Capability Assurance process in a safe manner through Root Cause Failure Analysis on high frequency and high-cost breakdowns and analysing maintenance performance.
SAFETY, HEALTH, ENVIRONMENT AND QUALITY:
Identify and assess level of issue-based risk exposures in area of responsibility by considering exposures to business, financial, legal issues, people, equipment, material, environment, processes, etc.
Consider the level of risk, apply mitigation and implement control measures for residual risk (set objectives, minimum requirements, etc.)
Manage SHEQ compliance within the Process through effective use of the Toolbox
Utilise the Integrated Management System (IMS) to initiate, investigate and report SHEQ status
Ensure the legislated safety, health and environmental standards are maintained
Perform FMECA and HIRA analyses on new plant equipment
Regularly review the FMECA and HIRA analyses on existing plant equipment
PEOPLE:
Supervise the Team:
Ensure an enabling climate/culture
Maintain labour stability by minimising labour turnover
Labour complement in line with budget
Manage performance against set targets and competencies
Ensure IDP’s are linked to performance results and implemented as per plan
Conduct career discussions and implement actions with all identified talent (quarterly)
Ensure discipline is maintained (absenteeism, lateness, overtime, misconduct, etc.)
Coach and counsel people to ensure improved performance levels
Conduct recruitment interviews.
CUSTOMERS:
Ensure Customer Satisfaction
Proactively seek ways of improving equipment reliability, planned maintenance and physical maintenance in the plant.
BUSINESS PROCESSES:
Maintenance Support:
Initiate task list reviews
Develop maintenance plans (frequencies, maintainable items)
Initiate plan review and review maintenance plans
Maintenance Data Analysis:
Perform Pareto analysis, correlation analysis and report top 5 chronic losses
Interview production personnel w.r.t. trips and artisans w.r.t. repetitive trips
Operational:
Ensure recognised and proper maintenance of the Conveyor Belt system to obtain 85% availability.
Ensure that the SAP PM data and work management meets Samancor Chrome standards at all times
Monitor corrective maintenance workload vs available manpower
Coach and mentor team members on effective Conveyor Belt system maintenance management
Create quality awareness and quality service awareness within the team
Provide regular feedback to the Engineer
Monitor and minimize overtime worked by team members
Compile and submit monthly Conveyor Belt performance report
Monitor and maintain HQMS procedures
Conveyor Belt Availability / Reliability:
Check uptime data, investigate where necessary and take corrective action
Keep record of breakdowns, callouts, spares usage, etc. for all Conveyor Belt systems.
Become totally integrated into the mining team to provide a comprehensive Conveyor Belt support service
Ensure that relevant Conveyor Belt spares and adequate quantities are kept in stock, and devise action plan to handle emergency situations
Establish a practical office management and filing system to promote good administration and record keeping.
Prioritise and plan work within the team structure
Compile preventative maintenance schedules on Conveyor Belt equipment.
Perform mean time between failures calculations and take steps to solve down-time problems
Implement modifications / upgrades / major repairs according to procedures
Standby:
Perform senior standby duties in area of responsibility
Report any Conveyor Belt breakdowns which have the potential to or has resulted in a lost blast or production loss during call outs immediately to the Engineer
Provide specialised on-site assistance to Belt personnel if requested
Solve problems and implement solutions:
Arrange RCFA investigation and facilitate the problem-solving session
Analyse alternative solutions & recommend best solution/s based on:
HSEC impact
Cost – risk – benefit analysis on key equipment performance parameters
Cost benefit to the organisation
Recommend best solutions to problems through the change management process
Record actions arising from RCA
Monitor recurring failures related to implemented RCA’s (KPI until close out)
Track Condition Monitoring (CM) results
Analyse equipment failure history
Log equipment problems identified for further action
Develop a list of clear problem statements and business cases for problems requiring RCA
Monitor and share Company-wide similarities / learning opportunities by using the Intranet Sites and SAP History
Monitor and advertise latest maintenance and technology developments
Develop, maintain and monitor adherence to maintenance standards and specification
Work Analysis:
Ensure the latest techniques are being applied with respect to NDT and condition monitoring
Advise in building reliability and maintainability in the design of new or modified equipment
Ensure sustained FLAC improvements
Contractor Management:
Develop detailed scope of work for defined scope jobs
Rotables Management:
Maintain Scope of Work data base (Specifications, Quality Plan, Witness points)
Costs
Regularly review cost reports, investigate over-expenditure and take corrective action
Overtime control
Strive for continuous improvement in the Belts effectiveness and availability through implementation of cost-effective technology
Keep abreast of latest equipment / technologies and trends.
GROWTH
Manage Continuous Improvement through Operational Excellenc
Requirements
MINIMUM REQUIREMENTS AND EXPERIENCE:
Degree B.Eng. / BSc (Mechanical or Electrical Engineering) or N6 Engineering or National Diploma in Engineering studies
6 years’ relevant experience
Additional:
Trade Certificate (Boilermaker / Fitter / Electrician)
Experience in Conveyor belt construction and maintenance.
KNOWLEDGE:
Demonstrate understanding of asset reliability improvement using root cause analysis and maintenance performance evaluation.
BEHAVIOURAL COMPETENCIES:
Safety Leadership
Innovation
Planning, Organising & Control
Results Orientation
Problem Solving & Decision Making
Relating & Networking
Change Leadership
Business Acumen
Apply via company website ( http://www.samancorcr.com ) or
samancor.mcidirecthire.com
To apply for this job please visit samancor.mcidirecthire.com.