Reliability, Inspection and Design Superintendent

JOB PURPOSE

The Reliability, Inspection and Design Superintendent is responsible for developing and implementing asset reliability strategies, inspection programs, engineering standards, and maintenance improvement initiatives to maximize equipment availability, safety, and asset life.The role leads reliability engineering, condition monitoring, equipment inspection, failure analysis, and maintenance optimization activities while providing technical support for plant modifications, upgrades, projects, commissioning, and operational excellence initiatives. A key focus is establishing asset management systems and reliability processes to support commissioning, ramp-up, and sustainable long-term operation of the concentrator plant.

MAIN TASKS, DUTIES AND RESPONSIBILITIES

RELIABILITY MANAGEMENT

Develop and implement site reliability strategies for fixed plant assets.

Lead Reliability Centered Maintenance (RCM) initiatives.

Establish asset criticality assessments and maintenance tactics.

Monitor reliability KPIs and drive improvement plans.

Develop long-term asset replacement and lifecycle management strategies.

Facilitate defect elimination programs.

Establish reliability standards, procedures, and engineering best practices across the maintenance department.

Facilitate regular reliability review meetings with Operations, Mechanical, and E&I teams

PERFORMANCE MONITORING

Develop and maintain asset performance monitoring systems for critical plant equipment.

Analyze equipment performance trends and identify opportunities to improve availability, reliability, and maintainability.

Monitor and report key performance indicators (KPIs) including equipment availability, OEE, MTBF, MTTR, maintenance costs, and reliability improvement targets.

Develop and maintain reliability dashboards and management reports.

Conduct performance gap analysis and recommend corrective actions.

Identify bad actors and recurring equipment failures through data analysis.

Support condition monitoring technologies including vibration analysis, oil analysis, thermography, ultrasonic testing, and online monitoring systems.

Collaborate with Operations, Mechanical, and E&I teams to improve plant throughput and equipment performance.

Benchmark maintenance and reliability performance against industry best practices.

Drive data quality improvements within CMMS/ERP systems to support effective decision-making.

Present performance reviews and reliability improvement initiatives to site leadership

INSPECTION & ASSET INTEGRITY

Develop and manage inspection programs for critical equipment.

Ensure statutory inspections are completed in accordance with regulatory requirements.

Manage structural, piping, pressure equipment, tanks, chutes, and conveyor inspections.

Coordinate non-destructive testing (NDT) activities.

Monitor corrosion, wear, fatigue, and equipment degradation mechanisms.

Maintain asset integrity records and inspection databases.

Lead the development and implementation of the site's Asset Management Framework aligned with ISO 55000 principles.

Maintain equipment criticality rankings and lifecycle management plans.

RELIABILITY ENGINEERING

Lead Corrective & Preventive Actions (CAPA) and Root Cause Failure Analysis (RCFA) investigations.

Conduct failure mode analysis and risk assessments.

Review equipment performance trends.

Drive predictive maintenance initiatives including

o Vibration analysis

o Thermography

o Oil analysis

Ultrasonic inspections

Motor current analysis

Identify bad actors and recurring equipment failures.

ENGINEERING & DESIGN

Review and approve engineering modifications.

Support plant improvement and debottlenecking projects.

Act as the technical authority for engineering modifications and management of change (MOC) processes.

Review OEM recommendations and approve engineering improvement opportunities.

Ensure compliance with engineering standards and specifications.

Coordinate design reviews and technical evaluations.

Support capital project development and execution.

COMMISSIONING & PROJECTS

Support equipment specification and technical evaluations.

Participate in FAT (Factory Acceptance Testing) and SAT (Site Acceptance Testing).

Support commissioning and plant performance testing.

Validate maintenance strategies for new assets.

Ensure operational readiness prior to handover.

LEADERSHIP & TEAM MANAGEMENT

Lead reliability engineers, inspection personnel, and technical specialists.

Develop technical competency programs.

Mentor engineering and maintenance teams.

Foster a culture of continuous improvement and technical excellence.

SAFETY & COMPLIANCE

Ensure compliance with company safety standards.

Support risk assessments and HAZOP studies.

Participate in incident investigations.

Ensure compliance with regulatory and asset integrity requirements.

Promote safe work practices and a zero-harm culture.

BUDGET & RESOURCES MANAGEMENT

Prepare and manage department budgets.

Monitor spare parts inventory and optimize stock levels.

Control maintenance expenditures while maintaining equipment reliability.

Assist with procurement of equipment/spares and services.

Manage and evaluate contractor performance.

Ensure contractor compliance with safety and quality requirements.

Review contractor scopes of work and service agreements along with other MMC teams.

DATA ANALYTICS & DIGITALIZATION

Utilize CMMS, condition monitoring, and operational data to identify reliability improvement opportunities.

Develop reliability dashboards and performance reporting tools.

Support predictive and prescriptive maintenance initiatives through digital technologies and advanced analytics.