Key Responsibilities Utilities Operations & Maintenance Oversee daily operations of all utilities equipment including: â Industrial boilers (5-ton units) â Ammonia refrigeration plants, glycol chillers & cooling towers â High-pressure compressors (up to 40 bar) and air dryers â Standby and production generators â Water treatment systems (sand filters, multi-stage filtration, chlorination systems) Ensure optimal performance of utilities through monitoring, inspection, and corrective action. Conduct troubleshooting on mechanical, electrical, pneumatic, hydraulic, and instrumentation systems. Maintain accurate running hour logs, utility performance records, and compliance documentation. Preventative & Planned Maintenance Implement, manage, and optimise preventative maintenance schedules for all utilities equipment. Prioritise and allocate maintenance tasks to artisans and technicians. Ensure critical spares availability and stock control to prevent downtime. Maintain calibration schedules for all instrumentation, sensors, transmitters, and control valves. Oversee maintenance shutdowns, planned servicing, and statutory inspections (boiler, pressure vessels, safety equipment). Instrumentation & Automation Support PLC/HMI troubleshooting (Siemens S7, VSDs, single-loop controllers). Assist with instrumentation calibration, settings, and fault finding (flow, level, pressure, temperature). Maintain backups of PLC programs, configurations, and control system documentation. Ensure integrity of automation systems used within utilities (burner controls, ammonia controls, pump systems, dosing systems). Health, Safety, Quality & Compliance Ensure all utilities operations comply with OHS Act, boiler regulations, and relevant SANS standards. Enforce permit-to-work systems, lock-out procedures, and confined space entry protocols. Maintain up-to-date safety files, service records, and statutory inspection certificates. Attend safety audits, quality audits, and participate in root cause investigations. Team Leadership & Administration Supervise utilities artisans, technicians, and contractors. Conduct daily planning meetings and allocate work based on production priorities. Report utilities issues, downtime, and solutions to the Engineering Manager. Manage overtime, attendance, shift planning, and performance of the utilities team. Prepare utilities reports, maintenance summaries, project updates, and compliance logs. Continuous Improvement & Projects Identify and implement utilities-related improvement projects to reduce downtime and energy consumption. Lead cost-saving initiatives on water, steam, air, ammonia, and refrigeration systems. Support commissioning of new utilities equipment and expansions. Optimise plant reliability through data-driven decision-making (5 Whys, failure analysis, FMEA). Minimum Requirements Qualifications Trade Test: Instrumentation Mechanician (essential) or Millwright or BTech Mechanical Engineer Technical qualifications: N6 or higher (advantageous) Boiler operation or boiler familiarisation certification (advantageous) Pneumatics, hydraulics, and PLC-related certificates beneficial Experience 10 years utilities and maintenance experience in manufacturing/FMCG/processing sectors Strong exposure to boilers, refrigeration plants, chillers, compressors, and water treatment systems Experience leading maintenance teams or utilities departments Proven track record of reducing equipment downtime and improving plant performance Technical Competencies Instrumentation fault finding & calibration PLC (Siemens S7) & HMI exposure Pneumatic & hydraulic systems VSDs & control valves Root cause analysis & problem-solving Utilities compliance and statutory inspections Strong understanding of mechanical and electrical systems Behavioural Competencies Strong leadership and mentoring ability High attention to detail Excellent communication & reporting skills Ability to work under pressure in high-volume manufacturing environments Proactive, solution-driven and safety-conscious Key Performance Indicators (KPIs) Utilities uptime & availability Planned vs. unplanned downtime Compliance with boiler, compressor, ammonia & OHS regulations Execution of preventative maintenance schedules Cost control & budget adherence Spares management effectiveness Performance of utilities team Reduction of energy & water usage Why This Role Is Critical The Utilities Foreman plays a central role in ensuring the reliability and safety of the entire manufacturing plant, protecting production uptime and ensuring compliance with safety and food manufacturing standards. This role directly influences efficiency, product quality, and operational performance.
