Job Vacancies at Lafarge Cement

About the Job 

• The role holder is requred to ensure effective Preventive Maintenance Management program is established and sustained in order to ensure availability and reliability of the equipment, promote the Lafarge (Holcim) maintenance processes, ensuring application of maintenance procedures, methods and best practices.

What you'll be doing

• Train and coach his team on preventive maintenance and maintenance routines.
• Manage preventive maintenance team, define the missions and objectives, carry out their performance reviews, promote the quality of the work, motivate his personnel, and facilitate communication and relationships (regular department meetings, reports to the hierarchy).
• Ensure the permanent update of the personal skills, develop and implement a training plan for his team.
• Provide daily added value execution ‘job plans’ to boost the effectiveness of execution crew.
• Prepares the plant maintenance budgets ensuring technical justification of maintenance operations; based on inspection and equipment history; including elaboration and control of the maintenance budget, ensuring planning and follow-up of costs; perform monthly gap analysis (actual vs. budget) and ensure technical justification for maintenance major operations.
• Participate in the 5-year plant development (investment) plan; prepare maintenance CAPEX, where necessary and follow up on approvals.
• Contribute to sourcing and purchasing of CAPEX and third party services: identify needs, provide technical requirements, support tendering, follow up service execution and commissioning, provide input for supplier qualification and evaluation.
• Contribute to NWC optimization by identifying critical parts (based on risk assessment and implementation of preventive maintenance routines on critical equipment’s) and establishing optimal stock levels of spare parts (through FMEA)
• Define equipment and component replacement strategy based on systematic risk evaluation.
• Promote the maintenance management system, ensuring application of maintenance practices; through the Reliability Committee, drive cross functional analysis of incidents and maintenance performance, implementing the action plans to improve both reliability and maintenance practices.
• Ensure planning and scheduling of maintenance operations, looking for the optimum use of resources, equipment availability and maintenance cost; coordinate with Head of Mechanical / Electrical departments, schedule and prepare weekly mechanical and electrical maintenance programs.
• Maintains and updates the preventive maintenance program and its master plan (especially inspection and lubrication programs), ensuring quality and relevance as well as its implementation.
• Schedule and prepare major shutdowns, inspection and lubrication programs; ensuring effective co-ordination with other departments.
• Monitors the implementation and execution of the preventive maintenance tasks and procedures.
• Ensure good working conditions and safety for maintenance operations; perform monthly plant risk analysis to determine the potential operational risk that can affect performance.
• Investigates repetitive problems and initiates preventive or predictive maintenance procedures. Support in coordinating reliability committee meetings for all plant sections.
• In collaboration with the production, inspectors, execution and planning engineer, prepare the plant weekly mechanical and electrical maintenance programs.
• Interface with other support function e.g. procurement, inventory, and Finance to achieve the plant target’s.
• Control lubrication and condition monitoring tasks of equipment and installations to identify needs of maintenance actions and reduce risks of unplanned downtime.
• Maintains equipment history and documentation; keep library updated and ensure equipment documentation is permanently updated “as built
• Ensures the utilization of feedback from inspection as the driver for maintenance operations.
• Ensure the utilization of feedback from inspection as the driver for maintenance operations.
• Collect and handle all the work requests and check for accuracy of technical information.
• Manage maintenance work order backlog.
• Ensure quality of technical specifications for spares and sub-contracted work
• Coordinates and supports OEM technical team during shutdowns and other specific installation activities.
• Liaise with OEM for technical support when required.
• Respect MAC-SAP standard; follow up weekly MAC-SAP targets (KPIs).
• Tracks maintenance KPI and compliance.
• Tracks plant TIS weekly/ month reports, compliance and efficiency.
• Tracks Production Patroller’s daily WBI reports, compliance and efficiency.

Who You'll be Working With

• Key interfaces, Stakeholders and Relationships: Maintenance Inspector, Maintenance Planner, Execution Engineers (Mechanical, Electrical, Instrumentation & Automation), Production Coordinator, Patrollers, Lubrication, Workshop, Utility, Procurement, Inventory, Finance.

Key Performance Indicators

• Zero accident for staff and contractors within Preventive Maintenance department.
• Achieve and maintain 90% availability of the main equipment (Cement Mills and Packers).
• 100% Compliance to Inspection Program.
• OCR of 0.85 for Lubrication Activities.
• 100% Achievement of Inventory value target as set by Industrial/Finance.
• The completeness and accuracy of the equipment files and history. And to keep current the Equipment Parts Catalogue on each piece of existing equipment and develop parts lists for new equipment installations.

What We Are Looking For

Professional competencies:

• B.Eng. Mechanical, Electrical and any other engineering related field plus 5-7 years of work experience in Cement manufacturing

Behavioural and/or managerial competencies:

• Strong analytical skills.
• Excellent communications skills
• Computer literacy is essential
• Result driven (reliability, cost)
• Attention to detail, accuracy and precision
• Good aptitude/Field work
• Ability to prioritise actions
• Leadership capabilities (people management skills)
• Ability to work with a cross functional team
• Curious, inquisitive, attention to details
• Accurate, meticulous, attention to cleanliness
• Able to take initiative based on sound problem solving skills

Technical Competencies:

• Good knowledge of the technical details of cement plant.
• Good knowledge on the operating principles of the key plant equipment.
• Strong problem-solving and trouble-shooting skills
• In-depth knowledge of Preventive and Predictive Maintenance Techniques
• Knowledge of safety laws and regulations
• Proficiency in use of computer and data processing packages (Ms Word, Excel, Project, PowerPoint)
• Ability to interpret engineering drawings and symbols
• Proficiency in the use of AutoCAD software, ability to produce engineering sketches and drawings.
• Ability to coordinate the preventive maintenance functions.

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About the Job

• The primary objective of the Mechanical Inspector is to monitor equipment condition on a continuous basis and analyze trends in order to ascertain the required maintenance interventions (mechanical, electrical, mobile equipment) necessary to maximize equipment reliability, performance and life expectancy, at the lowest possible cost, while maintaining the production functions.

What you'll be doing

• Take a lead in the enforcement of Lafarge safety rules and guidelines through Visual Felt Leadership (VFL) while ensuring adherence by Maintenance teams.
• Ensure the planned inspection of all plant equipment and initiate work orders based on inspection results, including safety checks. In case of anomaly, performs first analysis and defines priorities for each action.
• Monitor and co-ordinate condition predictors, for all critical equipment.
• Coach and develop other maintenance practitioners involved in Inspection and Execution functions.
• Liaise with production personnel regarding operating procedures, which have an impact on equipment.
• Performs follow-up inspections of new installations or repaired equipment and verifies tolerances in critical issues to assure compliance to acceptance standards and the PPM Guidelines.
• Follow-up and update preventive maintenance schedule.
• Validate and update equipment specification files and history sheet
• Evaluate and improve the preventive maintenance job plans (from supplier’s recommendation if existing), create and update the corresponding inspection job plans, in coordination with the planner
• Ensure systematic review, application and optimization of lubrication program.
• Contribute to the analysis of failures and problems, recommending corrective actions.
• Participate actively in troubleshooting equipment chronic problems and come up with effective solutions
• Participate in the maintenance on-call program
• The Inspector communicates regularly with the operations personnel to gain information on any problem or concerns they may have about equipment and the way it is affecting the process
• The Inspector generates work requests for all tasks identified in the inspection route and brings to the attention of the planner those that are urgent.
• Analysis of data collected, completed work orders, and process data in order to initiate appropriate maintenance work orders, which include a detailed scope of work.
• Active role toward cost budgeting, cost forecasting and control of department expenditures.
• Comply with EMS Methods Instrumentation activities
• Ensure involvement in the implementation and maintenance of integrated management system in the plant

Resources

Human Dimension

• Lubrication Technicians Planners and Execution Engineers.

Organisation Dimension

• Report to Methods Manager
• Interface with the following: Mechanical, Methods Electrical, Automation, Safety and Stores departments.
• The Methods Manager: To receive objectives & directives, analyze results and correct Possible anomalies.
• The Maintenance execution (Mechanical and Automation/Instrumentation): for equipment’s repairs and reception.
• Method: to request work and repairs to be done.
• Safety Officer: To liaise for accident prevention and inform about any problem that may occur on Clinker plant. Security: to inform and solve security problems.
• External bodies: PHCN, raw material, bricks and other production supplier

What we are looking for

• Must be a Certified Mechanical Inspector.
• Ability to coordinate the inspection, preventive, breakdown maintenance.
• Good planning skills.
• Commitment to the highest standards of safe work habits
• Good knowledge of safety laws and regulations.
•  Good Coaching Skill.
• Very good written and verbal communications skills –
• Level of education: Degree or equivalent in any engineering discipline (Mechanical Engineering as main subjects).
• 4/5 years postgraduate experience.

Technical Competencies

• Good knowledge of Inspection and execution functions.
•  Proficient in PPM systems both in theory and in practice.
• Able to take initiative based on sound problem solving skills.

Behavioral Competencies

• Good interpersonal relationship
• Demonstrated leadership skills via work ethics
• Ability to delegate and motivate, fairness, etc
• Result oriented

Managerial Competencies

• Team leadership skill
• Good aptitude for organization and communication
• Result oriented with high decision making capacity/ self-confidence
• High level of initiative Anticipative