Dangote Group
Manufacturing
Description
2. Key Accountabilities2.1 Plant Reliability
- Own and implement the plant-wide reliability strategy and annual reliability improvement plan.
- Ensure the reliability and availability of all critical production and utility equipment.
- Identify chronic and recurring failures and lead permanent elimination of their root causes.
- Lead Root Cause Analysis (RCA) for major breakdowns, repeated failures and significant production losses.
- Apply FMEA, fault-tree analysis, equipment criticality assessment and reliability-centred maintenance principles.
- Maintain a reliability register, assign corrective actions and verify their effectiveness and timely closure.
- Establish improvement plans for kilns, mills, crushers, fans, gearboxes, conveyors, separators and packing equipment.
- Ensure reliability and maintainability requirements are considered in equipment modifications, upgrades and capital projects.
- Develop, issue and control maintenance procedures, inspection standards, checklists and technical work instructions.
- Define the correct preventive, predictive, condition-based and corrective strategy for each maintainable asset.
- Optimize maintenance frequencies using failure history, equipment condition, operating duty and manufacturer recommendations.
- Prepare standard job plans showing scope, sequence, safety controls, manpower, tools, spares and estimated duration.
- Maintain the preventive-maintenance master plan and ensure compliance with Dangote engineering standards and statutory requirements.
- Standardize lubrication, alignment, balancing, torqueing, installation and equipment acceptance practices.
- Manage vibration analysis, thermography, oil analysis, ultrasound, motor-current analysis and other predictive techniques.
- Establish inspection routes, measurement points, alarm limits and reporting frequencies for critical equipment.
- Analyse condition trends, issue early warnings and ensure corrective work is raised before functional failure.
- Verify condition-monitoring findings after intervention and maintain complete equipment-health histories.
- Support annual, monthly, weekly and daily maintenance planning based on asset risk and production priorities.
- Define shutdown scope using inspection results, equipment condition, statutory requirements and production plans.
- Review shutdown job packages, resources, spare parts, contractor requirements, schedules and critical paths.
- Monitor shutdown execution, technical quality and schedule compliance, and escalate emerging risks.
- Lead post-shutdown reviews, record lessons learned and ensure technical closure of completed work.
- Lead multidisciplinary investigations into major failures and abnormal equipment stoppages.
- Determine immediate, contributing and systemic causes and assign measurable corrective and preventive actions.
- Control temporary repairs and ensure they are converted into approved permanent engineering solutions.
- Verify repair quality before equipment return to service, including alignment, balancing, clearances, torque and lubrication.
- Conduct acceptance inspections after major repairs and overhauls and assess contractor technical performance.
- Ensure disciplined use of SAP PM, Maximo or the approved computerized maintenance-management system.
- Maintain accurate equipment hierarchy, asset registers, bills of materials, task lists and maintenance plans.
- Monitor work-order quality, backlog, completion, failure coding, labour booking, material usage and technical closure.
- Analyse maintenance data and publish actionable dashboards covering reliability, availability, downtime, cost and risk.
- Use equipment history and cost data to support repair-versus-replacement and lifecycle decisions.
- Maintain equipment criticality rankings based on safety, environmental, production, quality and financial consequences.
- Identify critical spares using failure risk, lead time, interchangeability and business impact.
- Review stock parameters with Warehouse and Procurement and support technical evaluation and standardization of spares.
- Investigate premature component failures, supplier-quality concerns and obsolete equipment risks.
- Reduce unnecessary inventory without exposing the plant to unacceptable reliability risk.
- Set reliability and maintenance-method targets aligned with the plant business plan.
- Monitor maintenance cost by asset, department and tonne of cement and identify sustainable cost reductions.
- Quantify the operational and financial impact of breakdowns, poor performance and lost production.
- Prepare reliability budgets, forecasts, project justifications and monthly performance reports.
- Identify opportunities to extend asset life, improve efficiency and reduce total lifecycle cost.
- Coordinate with Production to plan interventions and minimize operational disruption.
- Work with Process and Quality teams to distinguish equipment failures from process and material-related problems.
- Coordinate integrated solutions across Mechanical, Electrical, Instrumentation, Automation and Civil teams.
- Support equipment selection, installation, commissioning and performance testing with Projects and Engineering.
- Promote operator basic care, autonomous maintenance and shared ownership of equipment condition.
- Ensure all maintenance methods comply with Dangote safety, environmental and quality requirements.
- Include risk assessment, permit-to-work, isolation and lockout/tagout controls in all relevant job methods.
- Stop any work that presents an unacceptable risk to people, the environment, equipment or product quality.
- Support statutory inspections and ensure contractors comply with plant safety and technical standards.
- Lead, coach and develop Methods, Reliability, Planning, Inspection and Condition-Monitoring personnel.
- Set clear responsibilities, objectives and performance expectations and conduct regular reviews.
- Identify competency gaps and implement technical training and succession plans.
- Build a culture of disciplined maintenance, data-based decisions, collaboration and continuous improvement.
- Bachelor's degree in Mechanical, Electrical, Industrial, Maintenance Engineering or a closely related discipline.
- Relevant certification in maintenance, reliability or asset management is an advantage.
- Typically, 10-15 years of maintenance and reliability experience in cement or comparable heavy industry, including leadership responsibility.
- Strong working knowledge of cement-plant equipment from quarry and crushing through pyroprocessing, grinding, packing and utilities.
- Demonstrated experience in maintenance strategy, shutdown management, RCA, FMEA, condition monitoring and CMMS.
- Sound understanding of maintenance budgeting, contractor control, spare-parts management and lifecycle costing.
- Reliability-centred maintenance and asset-management capability.
- Strong technical analysis and structured root-cause problem solving.
- Maintenance planning, scheduling and shutdown leadership.
- Condition monitoring and equipment-inspection knowledge.
- Commercial awareness, budgeting and cost control.
- Leadership, coaching, communication and cross-functional collaboration.
- High safety standards, integrity, accountability and ability to perform under production pressure.
Start hiring with Fuzu
Recruit better talent faster - on your own or with our support.
Explore recruitment platformJob search tips from Fuzu
Selected articles on cover letters, CV structure, and interview preparation.
