General Superintendent - Area Maint.

JOB PURPOSE:

• Manage & control the assigned plants’ maintenance activities and resources including shift maintenance optimally, safely & environment friendly to ensure requisite area physical assets’ deliver world class Availability & Reliability at minimum cost & risk to sustain EGA Operation 24X7 and for achieving or exceeding assigned plants’ production targets & plans.
• 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

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.

AUTHORITY/ DECISION MAKING:

Authority

Position holder uses the authority as defined in EGA delegation of authority and complies with company’s policies and procedures to accomplish assigned responsibilities.

Guidelines:

Thinking within generally defined policies, standards and objectives. Sets the plans for equipment maintenance to achieve required equipment availability at optimum maintenance cost. Lot of evaluation/judgement is required as issues/failures related to vast equipment differ every time.

Accountable along with operation counterpart to achieve or exceed production target of assigned area equivalent to 0.6 to 0.8 Million Ton per year of Finished/Equivalent Intermediate Products. Position holder performance directly impacts the area production which results in USD 1.25 Billion to USD 1.67 Billion Revenues at final product stage.

Position holder manages a total annual expenditure budget of about USD 5 to 10 Million and Area CAPEX Cash Flow of USD 2 to 4 Million ensuring an audited saving in the range of USD 200 to 250 K per year from the approved OPEX Budget.

3 to 4 Maintenance Supervisors directly report to the Job holder.

Leads a team of ~40 to 60 Supervisory & Non-Supervisory Persons to ensure the assigned area equipment is available for production at all the times.

Accountable to maintain, repair, overhaul & replace EGA Assets worth USD 0.4 to 1 Billion.

Accountable for spares inventory of USD 10 to 15 Million & its optimization.

Decision Making:

Work is subject to vision of Senior Vice President, direction set by the Vice President/Senior Manager and overall EGA Maintenance objectives & plans with complete freedom to decide how to achieve end results within the assigned area.

Decide Resource Allocation, Maintenance Priorities, Scope/Specifications of Maintenance Tasks, Repair vs. Replacement of Spares and Maintenance Plans.

QUALIFICATIONS & SKILLS:

Minimum Qualifications:

Bachelor’s degree in relevant field from a recognized institute/university. Master’s degree in Engineering or Business Administration is preferred.

Member of any one of the International Engineering/Maintenance Associations.

Minimum Experience:

At least 10 years of deep & multi-vocational practical maintenance, repair & overhauling experience in Heavy Industrial Equipment Environment preferably Smelting out of which at least 5 years are in a supervisory/superintendent role.

Skills:

Deep & multi-vocational knowledge of assigned area equipment & spares

In-depth knowledge of the centralised maintenance management system (SAP), maintenance strategies, root cause analysis & asset management

In-depth knowledge of engineering practices, standards and processes

In-depth knowledge of Budget Preparation & Control

Advance maintenance training on Control, Instrumentation, Networks & Automation Systems of various equipment/technologies

In-depth knowledge of Spare Parts Management

Out of box thinking

Strong maintenance project/contract execution skills

Excellent troubleshooting and problem solving skills

Strong people & conflict management skills

Good communication and interpersonal skills

Excellent training, development & performance management skills

Strong knowledge of environmental, health and safety standards/policies/legislations relevant to assigned area

In-depth knowledge of hazards & mitigation plans in assigned area

Hands on experience of lean principles, continuous improvement/innovation tools and systems