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The EMSTEEL Refractory Engineer will be the custodian of compliance to all refractory equipment and installation standards for EMSTEEL refractory protected assets.
- Work with Refractory teams to increase the operating availability and performance against reference rate of the asset.
- Facilitate Root Cause Analysis, determine root cause of equipment failure, and put in place actions to prevent reoccurrence.
- Analyses records, troubleshoots equipment problems, and makes procedure recommendations to operations and maintenance or implement engineering solutions.
- Facilitate and lead Root Cause Analysis & Failure Mode Element Criticality Analysis.
- Provide refractory engineering support in shutdowns
- Prepares cost and schedule estimates, and make recommendations as to the methodology, equipment, and material requirements as per asset life engineering.
- Ensure the monitoring of critical machinery, and otherwise identified equipment condition through the optimized use asset life prediction methodology.
- Ensure development of condition monitoring techniques as per market development and plant needs to ensure reliability of refractory.
- Documents technical work by setting up work plans and preparing appropriate records and reports.
- Optimizing critical spares inventory as per asset life design and engineering.
- Ensure new assets have refractory reliability incorporated into the design, and ensure operational readiness is obtained when commissioned.
- Provide leadership, training and coaching on Reliability and refractory standards and best practice.
- Ensure analysis, upkeep and recording of all equipment failures databases and supply analyzed information as to top failure modes and come up with engineering and management solutions to improve (MTBF) Mean Time Between Failure as per set plant targets and plant reliability.
- Ensure the analysis, upkeep and recording off all the high-cost equipment failures and supply engineering and asset strategy solutions to continuously improve budget costs on repairs and maintenance.
- Understand and identify critical and other equipment asset life cycle and upkeep information and initiate replacement when maintenance is no longer cost effective against capital replacement.
- Analyze operational data and machine performance history to identify and deliver improvement opportunities in machine performance, including decreasing unscheduled downtime, PM compliance, schedule compliance, mean time between failures, mean time to repair and maintenance costs, etc.
- Ensure all EMSTEEL refractory meets required standards.
- Provide input into site internal, external, and regulatory audits and investigations.
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- Ensure Optimized Asset Strategies focusing on Refractory Integrity & Reliability.
- Obtain approval and implement the Annual Plan, Policies & Procedures for the Reliability (Integrity) Department to enable the achievement of EMSTEEL agreed Business Objectives.
- Periodic review to align with Corporate Objectives. Initiate, Implement and Manage Plan.
- Provide professional advice and support to all levels of the business on Integrity related issues to ensure the production capability of the business is optimized.
- Leadership:
- Ensure the effective achievement of Refractory protection for Asset Integrity functional objectives through leadership and engineering.
- Budgeting & Cost Control:
- Assist in Preparation & Management annual budget and operating plans that accurately represent anticipated Integrity equipment maintenance & development costs to allow accurate business planning and cost management.
- Budgeting and Control includes followings:
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- Prepare, review and optimize Annual OPEX Budget requirement with proper justification for each of the Cost Centers of Integrity Related items.
- Prepare, review and optimize Annual CAPEX Budget requirement with proper justification for each of the Cost Centers of Integrity Related items.
- Operational Management:
- Liaise with external parties to understand legislative requirements and changes.
- Personally, resolve critical problem to minimize the production downtime.
- Respond to emergencies and ensure that operational targets are not unnecessarily prejudiced by breakdowns and losses are minimized.
- Provide technical input for the resolution of major refractory problem to minimize down time and enhance plant performance.
- Maintenance Planning:
- Develop the Refractory maintenance program in a systematic and predictive manner, so that the unplanned shutdowns are minimized.
- Recommend & coordinate with third party maintenance services provider to ensure availability of resources in a timely manner.
- Trend analysis of key maintenance parameters such as asset integrity, utilization, refractory cost, PM compliance etc.
- Capital Planning:
- Recommends capital expenditure in line with Asset Life strategies of refractory equipment to ensure physical capability to meet its strategic objectives.
- Direct the ongoing review of the physical condition of all physical assets in the Maintenance Department to ensure that those assets are in a suitable condition to allow the organization to fulfill its strategic objectives and they comply with any relevant legislation.
- Safety, Quality & Environment:
- Direct & follow-up all relevant safety, quality and environmental management policies, procedures, and controls across the Reliability Department to promote awareness on employee safety, legislative compliance, delivery of high-quality products / services and a responsible environmental attitude.
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- HSE responsibilities includes, but not limited to followings:
- Lead from front by ensuring all personal HSE Leading KPIs are met.
- Setting HSE KPIs for team & ensuring full compliance.
- Direct, Maintain and ensure Maintenance Team to follow EMSTEEL Health, Safety and Environment procedure through regular Audits and timely closure of H&S related Actions.
- Policies & Procedures:
- Direct the development of policies covering all areas of the Reliability department related to Refractory Integrity Items, so that all relevant procedural / legislative requirements are fulfilled while delivering a quality, cost-effective services to customers.
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