Senior Engineer - Crushing & Mills Maintenance مهندس أول - صيانة الكسارات والمطاحن

Brief Posting Description
The Senior Engineer – Crushing & Mills Maintenance is responsible for leading the maintenance, reliability, availability, and performance optimization of crushing, grinding, milling, screening, conveying, and associated plant equipment within mining and mineral processing operations.The role ensures safe, reliable, and cost-effective operation of crushing and milling assets through effective maintenance strategies, shutdown planning, reliability improvement initiatives, asset integrity management, and continuous improvement programs. The position provides technical leadership to maintenance teams, supports operational excellence, and maximizes equipment availability while minimizing lifecycle costs and production losses.
Detailed Description
CRUSHING & MILLS MAINTENANCE MANAGEMENT
Lead maintenance activities for crushing, grinding, screening, milling, conveying, and auxiliary plant equipment.
Ensure maintenance practices support safe, reliable, and efficient plant operation.
Develop and implement maintenance strategies to maximize equipment reliability and availability.
Monitor plant equipment condition and recommend corrective actions.
Ensure compliance with OEM recommendations and maintenance standards.
Support long-term equipment lifecycle management initiatives.
Provide technical guidance on maintenance planning and execution.
EQUIPMENT RELIABILITY & PERFORMANCE
Lead reliability improvement initiatives for crushers, mills, screens, conveyors, feeders, pumps, and associated equipment.
Analyze equipment failures and identify reliability improvement opportunities.
Conduct Root Cause Failure Analysis (RCFA) for major equipment breakdowns.
Facilitate Failure Modes and Effects Analysis (FMEA) studies.
Identify bad actors and implement corrective action plans.
Develop reliability-focused maintenance strategies.
Monitor equipment performance against reliability KPIs.
MAINTENANCE PLANNING & EXECUTION
Support development of annual maintenance plans and maintenance budgets.
Review preventive and predictive maintenance programs.
Optimize maintenance frequencies and task content.
Coordinate maintenance resources for planned and corrective maintenance activities.
Ensure maintenance work orders are properly executed and closed in SAP PM.
Improve work management processes and maintenance effectiveness.
Monitor maintenance backlog and prioritize critical activities.
SHUTDOWN & TURNAROUND MANAGEMENT
Lead preparation and execution of crusher, mill, and plant shutdown activities.
Develop shutdown scopes, resource requirements, and schedules.
Coordinate contractors and internal teams during shutdown execution.
Monitor shutdown progress and manage critical-path activities.
Ensure shutdown activities comply with safety and quality requirements.
Conduct post-shutdown reviews and lessons learned sessions.
ASSET INTEGRITY MANAGEME
Ensure mechanical integrity of critical crushing and milling equipment.
Monitor wear-life performance of liners, crushers, mill components, screens, and conveying systems.
Review inspection findings and establish corrective maintenance actions.
Support condition monitoring and predictive maintenance programs.
Participate in risk assessments and asset criticality evaluations.
Ensure compliance with asset management standards and engineering requirements.
TECHNICAL SUPPORT & TROUBLESHOOTING
Provide advanced troubleshooting support for major equipment failures.
Review vibration analysis, thermography, lubrication analysis, and condition monitoring reports.
Support operations in resolving equipment performance issues.
Evaluate equipment modifications and engineering improvements.
Review OEM recommendations and technical reports.
Support commissioning and startup of new equipment.
CONTINUOUS IMPROVEMENT
Drive continuous improvement initiatives to improve equipment availability and throughput.
Identify opportunities to reduce maintenance costs and unplanned downtime.
Implement Lean Maintenance and reliability improvement methodologies.
Develop business cases for equipment upgrades and reliability projects.
Track benefits realization from improvement initiatives.
Promote best practices across maintenance and operations teams.
SAFETY, HEALTH, ENVIRONMENT & QUALITY
Promote a strong safety culture within maintenance activities.
Ensure compliance with company HSE policies and statutory requirements.
Participate in incident investigations, audits, and risk assessments.
Ensure maintenance activities are carried out in accordance with approved procedures.
Support implementation of corrective and preventive actions.
Ensure compliance with quality and asset management standards.
CONTRACTOR MANAGEMENT
Supervise contractors engaged in shutdowns and maintenance activities.
Review of contractor performance and safety compliance.
Validate maintenance quality and technical deliverables.
Ensure contractor activities align with company standards and expectations.
PEOPLE LEADERSHIP & DEVELOPMENT
Provide technical leadership and mentoring to maintenance supervisors, planners, and technicians.
Develop team competencies related to crushing and milling equipment.
Support skills development and knowledge transfer initiatives.
Promote teamwork, accountability, and continuous improvement culture.
Support succession planning and capability development programs.
COST CONTROL & BUDGET MANAGEMENT
Support preparation and management of maintenance budgets.
Monitor maintenance expenditure against approved budgets.
Identify cost-saving opportunities without compromising reliability and safety.
Support lifecycle cost analysis and asset replacement decisions.
Develop business cases for maintenance and capital improvement projects.
Ensure effective financial governance and reporting.

Job Requirements
Education:
• Bachelor’s degree in mechanical engineering or a related field or higher Diploma
Experience:
• Bachelor’s Degree with 10+ years or Higher Diploma with 15+ years of experience in a Concentrator Plant/related process plant with similar type of equipment
• 8+ years of experience in the mining/processing industry or related.
• Proven track record of successfully managing maintenance in large-scale processing maintenance
Certifications: Candidates holding or pursuing any of the following certifications will have an added advantage
• Six-sigma (BB)
Technical Skills:
• Maintenance Experience in Crushers, SAG-Ball-HIG Mills is must
• Maintenance experience on Floatation Equipment, conveying equipment, De-watering equipment are added advantages
• Should have knowledge on maintenance strategies, CMMS/ERP systems, Reliability and Performance Management
Soft Skills:
• Fluency in English, with excellent written and verbal communication skills.
• Strong leadership and people management skills.
• Excellent negotiation and influencing abilities.
• Strategic thinking and problem-solving capabilities.
• Strong communication and stakeholder management skills.
• High ethical standards and commercial integrity.
• Ability to work effectively in a multicultural environment.
• Strong decision-making and organizational skills.
• Ability to manage multiple priorities and perform under pressure