Maintenance Supervisor Richards Bay
Resume:
PERSONAL INFORMATION
SURNAME: Chetty
FIRST NAMES: Shunmugam Kubendran
IDENTITY No.: 770**********
DATE of BIRTH: 22 January 1977
GENDER: Male
MARITAL STATUS: Married
NATIONALITY: South African
LANGUAGES: English/ Afrikaans
HEALTH: Excellent
DRIVERS LICENCE: Code 08
HOME ADDRESS: 36 Bauhinia Bend, Arboretum, Richards Bay, 3900
POSTAL ADDRESS: P.O. Box 2575, Richards Bay, 3900
CONTACT NUMBERS: 083-***-****
EMAIL: ad8e2b@r.postjobfree.com
CAREER OVERVIEW
My career spans over 26 years, I have accumulated a wealth of experience in the field of maintenance, specifically in Open Cast, Heavy Minerals Mining, and Smelters. My educational background is anchored by a Mechanical Engineering Diploma and the distinction of being Trade tested as a Fitter & Turner. Complementing this, I have successfully completed the Middle Management Development Program (MMDP), earning a Certificate in Business Management.
My proficiency extends to the effective utilization of 1SAP and SAP R/3 Work Management systems, reflecting my dedication to streamlined operations. Presently, I hold the position of Maintenance Coordinator at SOUTH32, Hillside Aluminium, where I oversee multifaceted responsibilities. These encompass the management of Long-Term Resources Contracts pertaining to Scaffolding, Rigging, and Boilermaker services. Additionally, I lead a team of electricians and fitters, directing their efforts in executing corrective maintenance during plant shutdowns.
Throughout my career, I have been consistently entrusted with the management of diverse teams spanning various disciplines, a testament to my leadership capabilities. My expertise lies in the meticulous planning of shutdowns, skilful coordination of both planned and unplanned maintenance activities, and the adept oversight of shutdown operations. In a prior role at Richards Bay Minerals – Rio Tinto, I spent 13 years as a Maintenance Controller, orchestrating the strategic planning and maintenance of mining equipment integral to wet and dry production operations.
EDUCATIONAL QUALIFICATIONS
National Diploma: Mechanical Engineering - Umfolozi College: Richtek
Trade Certificate: Artisan - Fitter and Turner - Richards Bay Minerals
Middle Management Development Program - Certificate in Business Management - Graduate Institute of Management and Technology
Current Studies: B. Business Administration 2nd year (UNISA)
ROLES AND RESPONSIBILITIES
SOUTH32 Aluminium SA Hillside Smelter
MAINTENANCE SUPERVISOR: Long Term Resource Contracts
July 2021 to Present.
In my role as a Maintenance Supervisor with a specialisation in Long-Term Resource Contracts, I have been responsible for supervising maintenance operations tied to extended service agreements and contracts aimed at sustaining the optimal condition of equipment, machinery, or facilities over an extended duration. This critical position requires a proficiency in contract management, budget oversight, and performance monitoring to guarantee the enduring reliability and longevity of organisational assets through the implementation of effective and sustainable maintenance practices. My focus has been on ensuring seamless coordination with external contractors, adherence to contractual obligations, and the continuous improvement of maintenance processes to meet the organisation's long-term objectives.
Contract Management:
Manage and oversee long-term maintenance contracts with external vendors or service providers.
Ensure compliance with contractual obligations, including service level agreements (SLAs) and performance metrics.
Budget Oversight:
Collaborate with the finance department to develop and manage budgets for long-term maintenance contracts.
Monitor expenditures to ensure adherence to budgetary constraints.
Resource Allocation:
Allocate human resources effectively, ensuring that the right skills are available for the contracted maintenance services.
Coordinate with other departments to optimize resource utilization.
Quality Assurance:
Establish and enforce quality standards for maintenance services outlined in long-term contracts.
Conduct regular inspections and audits to ensure compliance with agreed-upon maintenance protocols.
Performance Monitoring:
Implement key performance indicators (KPIs) to assess the performance of maintenance contractors.
Regularly review performance metrics and address any deviations or concerns.
Communication with Contractors:
Maintain open and effective communication with external contractors.
Address concerns, provide feedback, and ensure that contractors are aligned with organizational goals.
Documentation and Reporting:
Keep detailed records of maintenance activities performed under long-term contracts.
Generate regular reports for management, highlighting contract performance, issues, and resolutions.
Training and Development:
Identify training needs for both in-house and contracted maintenance staff.
Facilitate training programs to ensure that personnel are equipped with the necessary skills.
Safety and Compliance:
Ensure that contracted maintenance services adhere to safety regulations and organizational standards.
Conduct regular safety audits to assess and mitigate potential risks.
Continuous Improvement:
Identify opportunities for process improvements within the context of long-term maintenance contracts.
Work with contractors to implement best practices and enhance overall efficiency.
Renewal and Negotiation:
Evaluate the performance of long-term maintenance contracts in preparation for renewal.
Participate in contract renegotiations, ensuring terms remain favourable to the organization.
Emergency Response:
Collaborate with contractors to develop and implement emergency response plans.
Ensure quick and effective responses to unexpected maintenance issues to minimize downtime.
SOUTH32 Aluminium SA Hillside Smelter
MAINTENANCE SUPERVISOR: HEAVY MOBILE Workshop
July 2020 - June 2021
In my capacity as a Maintenance Supervisor for Heavy Mobile Equipment, my responsibilities extended to overseeing the maintenance operations for a specialised fleet of heavy mobile machinery, including heavy-duty smelter vehicles, trucks, bulldozers, excavators, and other substantial equipment. A key facet of my role was ensuring the reliability, safety, and efficiency of this diverse fleet through meticulous planning, vigilant supervision, and the implementation of effective maintenance practices. This encompassed coordinating routine maintenance, addressing mechanical issues promptly, and fostering a culture of safety and excellence among the maintenance team.
Maintenance Planning:
Develop and implement comprehensive maintenance schedules for heavy mobile equipment.
Plan and coordinate routine maintenance, preventive maintenance, and major overhauls.
Supervision and Leadership:
Supervise a team of maintenance technicians and mechanics.
Provide leadership, guidance, and support to ensure efficient and effective maintenance operations.
Resource Allocation:
Allocate human and material resources effectively to meet maintenance demands.
Optimize the utilization of personnel and equipment to maximize productivity.
Equipment Inspections:
Conduct regular inspections of heavy mobile equipment to identify maintenance needs.
Utilize diagnostic tools and technologies to assess the condition of machinery.
Repairs and Troubleshooting:
Oversee the diagnosis and troubleshooting of mechanical, electrical, and hydraulic issues.
Coordinate and execute necessary repairs to minimize downtime.
Safety Compliance:
Ensure that maintenance activities adhere to safety regulations and protocols.
Promote a culture of safety among maintenance personnel and operators.
Documentation and Record Keeping:
Maintain detailed records of maintenance activities, including work orders, repairs, and inspections.
Generate reports on equipment performance, downtime, and maintenance costs.
Training and Development:
Identify training needs for maintenance staff to enhance skills and knowledge.
Facilitate training programs to keep the team updated on new technologies and best practices.
Spare Parts Management:
Manage inventory of spare parts and replacement components for heavy mobile equipment.
Coordinate with procurement to ensure timely availability of necessary parts.
Budget Management:
Assist in the development and management of the maintenance budget.
Monitor expenses, identify cost-saving opportunities, and ensure budgetary compliance.
Performance Monitoring:
Implement key performance indicators (KPIs) to assess the performance of heavy mobile equipment.
Regularly review performance metrics and implement improvements as needed.
Collaboration:
Collaborate with other departments, such as operations and logistics, to coordinate maintenance activities.
Communicate effectively with equipment operators to gather feedback on equipment performance.
Emergency Response:
Develop and implement emergency response plans for unexpected equipment breakdowns.
Coordinate rapid responses to minimize downtime during unplanned outages.
SOUTH32 Aluminium SA Hillside Smelter
MAINTENANCE CO-ORDINATOR: CARBON PLANTS
September 2013 –30 June 2020
Paste Plants Anode Bake Furnaces Rodding Shop Bath Plant Carbon Recycling Gas Treatment Centers Fume Treatment Centers Pitch Plants Harbour & Logistics Laboratory Impoundment Dams Casthouse Heavy Mobile Equipment Workshop
In my capacity as a Maintenance Coordinator, I assumed a vital role in supervising and organising maintenance activities within my organization. My responsibilities included the coordination of diverse elements of maintenance to guarantee the proper upkeep and functionality of equipment, machinery, and facilities. In this pivotal position, I focused on streamlining maintenance processes, optimising the utilisation of resources, and ensuring the overall reliability and functionality of the equipment and facilities under my purview. This involved meticulous planning, effective communication, and a commitment to fostering a culture of efficiency and excellence within my designated areas of responsibility.
Plant Maintenance Management:
Managed a diverse team of skilled artisans, including Millwrights, Electricians, Instrumentation Mechanicians, Diesel Mechanics, Auto Electricians, Fitters, Boilermakers, and Riggers.
Oversaw specialist vendors and contractors.
Managed Long Term Resource Contracts for Scaffolding, Rigging, and Boilermaking.
Maintenance Planning and Execution:
Directed Mechanical, Electrical, Instrumentation, and Structural maintenance, including preventative, corrective, and breakdown maintenance.
Led shutdown maintenance and managed abnormal and ad-hoc tasks.
Responsible for task scoping, meticulous planning, scheduling, and resource allocation.
Ensured safe and timely task completion while upholding quality standards and optimizing turnaround times.
Collaboration and Prioritization:
Collaborated with production counterparts to identify plant-wide priorities.
Ensured safe, efficient, and cost-effective coordination and execution of plant activities.
Budget Management:
Prudently controlled and managed the maintenance budget.
Successfully reduced vendor callouts and standby artisan costs through labour and skill deployment optimization.
Leadership and Team Development:
Provided guidance and leadership to the team, emphasizing safety and professionalism.
Promptly addressed breakdowns to optimize plant availability.
Maintained high standards of performance, behaviour, training, and development.
SAP Work Management:
Proficient in SAP Work Management, including creating Notifications for Maintenance & Operations.
Generated Purchase Requisitions and managed Vendor Contracts.
Expertise in Bills of Materials (BOMs) management.
Sourcing and Purchasing:
Actively participated in sourcing, purchasing, and overseeing spares delivery.
Prioritized continuous updates of BOMs.
Supported the Reliability team in various aspects.
Safety and SHEQ:
Monitored and mitigated safety risks and managed SHEQ processes.
Conducted Safety Audits for Breakdown and Adhoc tasks.
Maintained and enhanced safety, health, and environmental standards.
Administrative Tasks:
Managed maintenance-related data, documentation, and records.
Conducted failure and root cause analysis.
Identified opportunities for improvements in equipment availability, reliability, product quality, and cost reduction.
Safety Procedures:
Developed and compiled Risk Assessments, Method Statements, Job Task Analyses, Safe Working Practices, and Standard Work Procedures.
Regularly reviewed Risk Assessments to maintain safety standards.
Housekeeping and Organization:
Emphasized good housekeeping, maintaining a tidy and organized working environment.
Focused on fostering high team member morale, safety awareness, plant integrity, and workshop practices.
RIO TINTO Richards Bay Minerals
MAINTENANCE CONTROLLER: Reliability & Maintenance
Management - SMELTER & MINE August 2002 – June 2011
My role as a Maintenance Controller during this period was crucial in ensuring the
efficient and safe operation of the plants and facilities in my designated areas. It
required strong managerial and technical skills, as well as a focus on safety and
continuous improvement.
Plant Maintenance Management:
Responsible for planning and executing maintenance activities in various plant areas, including Slag Plant, Iron Plant, CPA Roster, Char Plant, Smelter, MSP, ZTP, Main Sub, and Mining Plants. This involved overseeing a team of multi-disciplined Artisans, including Fitters, Electricians, Boilermakers, Riggers, semi-skilled mechanics, specialist vendors, and contractors.
Shutdown Planning and Execution:
Attended daily shutdown meetings for different plants and prepared Gantt charts for shutdown execution. You assigned and scheduled resources for these shutdowns.
Quality Assurance and Problem Resolution:
Followed up on maintenance work issues, including comebacks, and conducted Root Cause Analyses (RCAs) and post-mortems to address problems and improve future shutdowns.
Technical Feedback and Reporting:
Maintained daily records of technical feedback and reported on Works Order Compliance, Artisan Utilization, Incomplete Planned Works Orders, and Scheduled Works Orders per artisan.
SAP Work Management:
Used the SAP system for work management, which involves maintaining records of work orders and tracking progress.
Resource Management:
Was responsible for capturing overtime, leave, and other HR-related issues for the artisans. You worked on controlling and maintaining the maintenance budget, optimizing labour and skills to reduce callouts to vendors and standby artisans.
Safety and Health Management:
Safety was a significant part of my role. Monitored and mitigated safety risks, ensuring that safety, health, environmental, and quality (SHEQ) processes were effectively managed. Conducted timeous and regular safety audits on planned and ad-hoc tasks to maintain and improve safety standards.
Documentation and Procedures:
Was responsible for compiling and developing various safety-related documents, including Risk Assessments, Method Statements, Job Tasks Analysis, Safe Working Practices, and Standard Work Procedures. Regular review of Risk Assessments ensured continued safety improvements.
Housekeeping and Workshop Practices:
Emphasized good housekeeping, maintaining a tidy and organized working environment. This helps in ensuring high levels of team member morale, safety awareness, plant appearance, and integrity, as well as efficient workshop practices.
RIO TINTO Richards Bay Minerals
MAINTENANCE ARTISAN: Reliability & Maintenance
Management - SMELTER & MINE December 2000 – July 2002
In my role as a Maintenance Artisan in a smelter, I played a pivotal role in guaranteeing the efficient operation of equipment and facilities. My responsibilities encompassed a diverse range of tasks, including maintenance, repairs, and optimization of machinery and systems within smelting and mining plants. Possessing a blend of technical skills, problem-solving acumen, and a steadfast commitment to safety, I ensured the reliable and uninterrupted operation of the facilities under my care.
Equipment Inspection:
Regularly inspect machinery and equipment to identify signs of wear, damage, or malfunction.
Utilise testing equipment to assess the condition of components and systems.
Preventive Maintenance:
Develop and implement schedules for preventive maintenance on key equipment.
Perform routine maintenance tasks to prevent breakdowns and extend equipment lifespan.
Repairs and Troubleshooting:
Diagnose and troubleshoot mechanical, electrical, and hydraulic issues in smelting equipment.
Execute necessary repairs to ensure continuous machinery operation.
Machine Overhauls:
Participate in major equipment overhauls during scheduled shutdowns.
Disassemble, repair, and reassemble machinery and components as needed.
Welding and Fabrication:
Perform welding and fabrication tasks for equipment repair or modification.
Ensure welding work meets safety and quality standards.
Alignment and Calibration:
Align and calibrate machinery for proper functioning and optimal performance.
Use precision tools and instruments to achieve accurate alignment.
Documentation:
Maintain detailed records of maintenance activities, repairs, and equipment inspections.
Update equipment manuals and documentation as changes occur.
Spare Parts Management:
Monitor and manage spare parts inventory and replacement components.
Order necessary parts and maintain an organised spare parts storage area.
Safety Compliance:
Adhere to safety protocols and guidelines during maintenance tasks.
Identify and report potential safety hazards, participating in safety training.
Collaboration:
Collaborate with other maintenance technicians, engineers, and operations personnel.
Communicate effectively with different departments to coordinate maintenance activities.
Training:
Stay informed about new technologies and maintenance best practices.
Train and mentor junior maintenance staff.
Emergency Response:
Respond promptly to equipment breakdowns and emergency situations.
Work efficiently to minimize downtime during unplanned outages.
WORK EXPERIENCE
MAINTENANCE SUPERVISOR: Long Term Resource Contacts
South32 – Hillside Aluminium
Maintenance Department
Boilermaking/ Rigging/ Scaffolding/ Shutdown Team
July 2021 – Present
MAINTENANCE SUPERVISOR: Heavy Mobile Workshop
South32 – Hillside Aluminium
Maintenance Department
Mobile Workshop
July 2020 – June21
MAINTENANCE CO-ORDINATOR: SHIFT
South32 – Hillside Aluminium
Maintenance Department: Carbon - Paste Plants/ Anode Bake Furnaces/ Rodding Shop/ Bath Plant/ Carbon Recycling/ Gas Treatment Centers/ Fume Treatment Centers/ Pitch Plants/ Harbour & Logistics/ Laboratory/ Impoundment Dams/ Casthouse/ Heavy Mobile Equipment Workshop
September 2013 – June 2021
MAINTENANCE SUPERVISOR
BHP Billiton – Hillside Aluminium
Maintenance Department: North
Bath Plant & Anode Recycling
December 2012 - August 2013
MAINTENANCE SUPERVISOR
BHP Billiton – Hillside Aluminium
Maintenance Department: South - Casthouse & Water Plant
July 2011 – November 2012
MAINTENANCE CONTROLLER
Rio Tinto - Richards Bay Minerals
Reliability & Maintenance Management - Maintenance & Execution
August 2002 – June 2011
MAINTENANCE ARTISAN
Rio Tinto - Richards Bay Minerals
Reliability & Maintenance Management - Maintenance & Execution
December 2000 – July 2002
APPRENTICE: Fitter & Turner
Rio Tinto - Richards Bay Minerals
February 1998 – November 2000
COURSES AND TRAINING COMPLETED
SAP R3
1 SAP (BHP Billiton – Hillside Aluminium)
MMDP: Middle Management Development Programme
Project Management
Maintenance Planning
MS Projects
MS Excel
MS PowerPoint
OSH ACT
Electrical multi-skilling
6 Sigma Training (Yellow Belt)
Reliability Centred Maintenance
Root Cause Analysis
Condition based/ Predictive Maintenance - CBM (vibration, tribology, infrared, ultrasonic)
Zero Harm / Incident Process
ICAM: Incident Cause Analysis Method
Conflict Management
Situational Leadership
Problem Solving
Business Finance
Business Literacy
Safety for Supervisors
Safety Observation and Coaching
Risk Management
Legal Liability
Codes of Practice
Confined Space Entry
Working at Heights
First Aid Training
Lockout Training
Mission-Directed Work Teams – Mini businesses
Effective Supervision
2.9.2 Training: Roles & Responsibilities
Defensive Driving
Employment Equity
Basic Lube Training
Environmental Awareness Employee Relations Training: Supervisory
Basic Fire Training
Electrical Hazards Training
Accident Investigation
Occupational Hygiene and Awareness
Laser Alignment
Hydraulic Maintenance & Fault-finding
Safety Representative Training
Train the Trainer Facilitation
Personal and Interpersonal Leadership
Business Code of Conduct
REFERENCES
Mr Kevin Brooks
Manager: Maintenance
South32 – Hillside Aluminium
Mr Sizwe Thwala
Superintendent: Maintenance
South32 – Hillside Aluminium
Mrs Aziza McKenzie
Superintendent: Maintenance
South32 – Hillside Aluminium
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