Mechanical Maintenance Engineer – DR-1

KEY ACCOUNTABILITIES:

Description

Technical Maintenance Activities

• Analyze the daily maintenance activities from the daily log books and record sheets versus the plan and make any required modifications to subsequent daily plans in order to support the achievement of the maintenance plans.
• Analyze the vibration and maintenance result sheet, identify, design and propose to management technical maintenance improvements and/or equipment developments in order to support the continual technical improvement of maintenance provision.
• Identifying and addressing technical problems with implementing solutions for rectification.
• Conducting technical research and applying new knowledge.
• Study and review engineering designs for new projects and identify the variations
• Prepare Tender documents for CAPEX projects, evaluate the Technical Offers, schedule the project timeline and cash flow, coordinate with internal and external parties for execution, monitor the progress and confirm the project completion according to the approved schedule.
• Interact daily with the operation team to interpret their needs and requirements and represent them in the field.
• Carry out and supervise all maintenance programs for critical and/or complex plant equipment including all types of mechanical equipment in order to ensure that continuous plant availability and equipment downtime is minimized.
• Confirm execution of all maintenance program (Preventive, Predictive, Breakdown) with the plant /shift supervisor in order to ensure the achievement of high standards of plant and equipment operation with minimal production downtime
• Communicate and co-ordinate with vendors, technology suppliers & third parties for all plant know-how issues, troubles, upgrading & modifications in order to ensure that maintenance provision meets the ongoing needs of the production process.
• Identify and recommend equipment / systems for procurement, provide technical specification, perform technical evaluation of equipment and suppliers and ensure effective commissioning and follow up where appropriate.
• Manage discrete projects and support / contribute to larger projects, e.g. internal expansion, from feasibility study through to implementation in order to ensure that projects are delivered to time, cost and quality standards
• Apply engineering technical knowledge and skills in Mechanical maintenance in various aspects of applications
• Identify and evaluate opportunities to import substitution for challenges like high cost, obsolete spare parts to ensure the reliability of the asset.

Planning

• Prepare maintenance annual plans activity in order to ensure the achievement of high standards of plant and equipment operation with minimal production downtime.
• Plan, identify and recommend equipment / systems /spares for procurement, provide technical specification, perform technical evaluation of equipment and suppliers and ensure effective commissioning and follow up where appropriate.
• Prepare long term maintenance plan for own area, for management approval, in order to ensure that plant and equipment maintenance needs are met and production process availability optimized for the coming 5 years.

Budgeting & Inventory Control

• Prepare and propose annual budget OPEX /CAPEX figures for management approval that accurately represent anticipated costs and enable effective cost management
• Monthly review for the budget consumption figures for mechanical to be in line with the approved budget consumption plan.
• Control the record management systems to manage inventory holding including its costs and to ensure that minimum stock is available all the time without unnecessary duplication.
• Review the monthly shift schedule plan to ensure the overtime within the approved budget .

Supporting Activities

• Support and provide guidance to his team in technical studies to contribute to ongoing development of maintenance and operation activities to ensure the technical problems are effectively resolved.
• Support management in achieving the targets of company corporate objective such as safety, profitability and sustainability.

Data Recording and Analysis

• Periodical review of inspection results and perform data analysis to predict the expected troubles and ensure that plant and equipment data is available and well analysed.
• Ensure all the data records follow relevant certifications such as ISO-9001, 14001, 45001 etc.

Reporting

• Prepares the reports to management with the data analysis and recommendations to achieve the best performance in all manners.
• Report technical abnormalities with recommendations to the management in order to ensure senior management have sufficient information to support decision making and giving direction for appropriate remedial action and / or planning of future maintenance activity.
• Review of delays and fault reports for root cause analysis corrective actions

Continuous Improvement

• Identify and develop improvements to operating standards, policies, and procedures to support continuous improvements in operating performance.
• Lead and promote technical development in equipment and process maintenance in order to ensure continuous improvement in operation and achieving maintenance KPIs.

Health, Safety & Environment

• Identifying hazardous situations and evaluate the relevant risk in order to conclude appropriate action to maintain safe working environment.
• Confirm compliance with all relevant safety, health and environmental procedures and raise any of HSE concerns and incidents to HSE with the recommended actions to ensure safe work practices and environment and to achieve corporate Zero Harm Objectives.
• Continuously review operating and safety standards and procedures (HIRA/PTW/LOTO/TBT . . . etc) in DR-M area, updating and modifying as appropriate under the direction of the Section Head
• Contribute in all PSM and HAZOP studies in DR-M plants.
• Prepare annual plan for monthly safety meeting and attend all safety patrols & meeting.
• Review the reported observations in the monthly safety activities in the department including HES safety patrol, MRM, fire drill and environment audit and confirm its closing action plan in order to ensure any HES operating issues are understood and appropriate corrective action is taken

Policies, Processes and Procedures:

• Monitor compliance to applicable codes, practices, QA/QC policies, performance standards and specifications
• Draft all Standard Operation Procedures for all maintenance activities in his area.
• Confirm the continuous process of reviewing the operating and safety standards and procedures, updating and modifying as appropriate under the direction of the Maintenance Section Head
• Identify and design system to ensure all operating, safety, environment, and quality procedures are followed to ensure the highest standards of operational integrity are achieved.
• Follows all relevant policies, processes, standard operating procedures and work instructions in the section so that work is carried out in a controlled and effective manner.

Related Assignments

• Perform and carryout any additional assignment /tasks as required by management.

QUALIFICATIONS, EXPERIENCE, & SKILLS:

Minimum Qualifications:

• University Bachler degree in Mechanical Engineering

Minimum Experience:

• Minimum 7 years of experience in Midrex Direct reduction plant

Job-Specific Skills (Generic / Technical):

• In depth specialist skills and knowledge in own engineering specialism plus well-developed knowledge and understanding of the entire production operation
• Comprehensive understanding of DR process, associated function areas and understanding of all Steel Making Plants.
• Well-developed analytical skills.
• Complete knowledge in centrifugal compressors, rotary lobes blowers.
• Complete knowledge of static equipment (pipes, vessels etc.) maintenance best practices.
• Complete knowledge of DR plant hydraulic system maintenance.
• Comprehensive knowledge and understanding of safety, environment and quality system procedures and standards
• Comprehensive knowledge and understanding of HSE and quality procedures and standards.
• Complete Knowledge and understanding of process calculations and computations.
• Ability to read and interpret technical drawings and documents.
• Planning and organising skills.
• Ability to work both as part of a team and independently, on own initiative.
• Problem solving skills and Decision Maker/Taker
• Ability to understand financial planning and budgeting processes.
• Communication skills - written and verbal.
• Technical and business report writing skills.