Overview:
The main objectives of the role are to ensure that the maintenance program and strategies are delivered across the Little Island site over 24/7. The shift team lead is responsible for ensuring machinery used to produce our concentrate products run to their maximum efficiency and output. This includes total preventative maintenance, managing breakdowns of mechanical, electrical, and robotic equipment (including software programming) across 24/5 operation with some systems running 24/7. This role includes people management and budgetary/cost reporting. The position involves working with the various functions/teams to perform maintenance work across each working shift. The maintenance shift team lead is responsible for ensuring that all proactive maintenance activities that are planned and scheduled are completed on time and tracked in an efficient and effective manner on the SAP PM system. They must be able to anticipate potential problems before they arise (defect prevention and avoidable delays) and create a plan of action to address them.
The team lead responsibilities include ensuring that the maintenance shift team follow the company’s rules and policies across 24/5 operation including training and orienting new employees to the team.
The position requires a high level of technical skills and knowledge of various crafts such as Electrical, Mechanical, plumbing, Process etc. Leadership and knowledge of administrative tasks such as scheduling are also essential.
The responsibility is to ensure that all plant equipment is always maintained to the highest standard and in excellent and safe condition at all times of use. Since 2017 the Maintenance has several monthly KPI targets ensuring the site complies to the Global program. Over the last number of years, the maintenance function has implemented several Global Engineering and H&S standards across the site, and it is important that the maintenance team adhere to these. As of 2024 the maintenance programme requires the team to work a 24/5 shift pattern and each shift will be required to completed planned works in an efficient manner.
The site at Little Island has grown significantly over the last number of years with additional equipment and process rooms added to the facility, the maintenance strategy has also evolved to allow us to deliver the business targets such as Quality, H&S and operations targets as well as the Maintenance targets. The various maintenance strategies deployed are in a constant state of evolution given the increasing complexity of manufacturing equipment and processes. In Little Island plant we use a combination of reactive maintenance (RM), preventive maintenance (PM), predictive maintenance (PdM), and proactive maintenance (PaM) to maintain our fleet of assets, in which the maintenance strategy for a given asset depends on the complexity of the machine and the impact an unexpected failure has on that machine. Due to the increase in maintenance activities, we are no longer able to fulfill our requirements with current resources or shift pattern. As a result, we are building a new programme around a 24/5 shift pattern and additional craft team members to execute.
The business demand for plant equipment and process equipment has also increased with a focus on T/E (true Efficiency) as a result there is a greater focus on equipment failure and breakdown recovery. The team lead will be responsible for day-to-day activity working with the operations shift lead to ranking works based on operational demands and information via shift meetings (W@POA) and efficiency reports.
Responsibilities:
- Reporting to the Maintenance senior supervisor, the maintenance shift team lead will coordinate the day to day reactive, preventive maintenance and statutory compliance schedules across shifts.
- Lead the Maintenance Shift Team in the repair of day-to-day equipment and system issues to minimise downtime. Support the Maintenance continuous improvement culture through team participation in various initiatives across the technical function.
- The maintenance shift team lead will organise the reactive, preventive maintenance and statutory compliance schedules for plant equipment and facilities across the Little Island site.
- Co-ordinating the frontline craft shift team on repair and maintenance of facilities and plant equipment across the site, including various contractors/ vendors. This includes review of method statements, risk assessments, LOTO and issuing of work permits and review and signoff of service reports etc.
- Liaise with production on machine uptime and availability of equipment and drive machine performance through data review and performance metrics of the Maintenance teams across each shift.
- Lead the Maintenance team in implementing the plant preventive maintenance schedule and ensure preventative maintenance system is kept up to date based on functional KPI’s.
- Provide leadership and supervision to the Maintenance team in the maintenance, repair, modification and continuous improvement, project support, installation and testing of all types of plant equipment and automation systems. Plan out and assign work. This will involve delegation of assigned work task to individual craft members and ensuring timely completion of same.
- Provide technical support to each function on day-to-day activities and across shift, manage and process high volume of calls and request.
- Support the maintenance department in problem solving, root cause investigation and major breakdown reports, reliability centred maintenance, update shift handover to reflect daily issues/challenges. Developing robust detailed handover reports at the end of shift and lease with incoming shift on key priorities and watchouts.
- Support project & equipment handover, ensure all new equipment is added to CMMS and all maintenance work tasks are developed as per recommendation (site requirements, vendor recommendations etc).
- Support daily/weekly shift meetings and other site initiatives across 24/5 operation.
- Adhere to all the H&S and Quality requirements in site by actively leading the team in the sites drive to Health and Safety Excellence and culture-based system journey.
- Ensure delivery of the maintenance weekly plan and compliance to the global monthly Maintenance KPI’s.
- Min 5 years technical experience in a manufacturing environment with significant people management of frontline unionized employees.
- Ability to track and manage ordering of supplies, services and spare parts.
- Solid understanding and experience of Plant and facilities technologies.
- PLC & SCADA control system.
- Fire Alarm and fire protection system.
- Air handling & HVAC system.
- Boiler and compressed air systems.
- Computer skills required include MS Office/ Excel/ PowerPoint/MS Teams.
- Ability to analyse service reports and statutory compliance requirements and manage multiple priorities in a timely manner, with precise attention to detail and a high degree of accuracy.
- Observe HSE regulations, encourages safe working practices and assist in compliance reviews, general risk assessments and other safety assessments to support Health, Safety and Environmental management.
- Demonstrated experience working with computerized maintenance management systems (SAP PM).