Aphelele Mlomzale

Mine Health & Safety Act Statutory Compliance

• Upheld full statutory compliance in accordance with the Mine Health and Safety Act through routine inspections, audits, and execution of all corrective actions within my area of responsibility.
• Ensured the safe installation, proper operation, and continuous maintenance of all machinery, fulfilling my legal duties as an engineer appointed under Minerals Act Regulation 2.13.3.1.
• Maintained all safety appliances, guards, and protective mechanisms in sound working order, conducting field verification and technical reviews to mitigate equipment-related risks and ensure plant integrity.
• Oversaw the safe erection and maintenance of all buildings, structures, and tanks, ensuring engineering designs and workmanship complied with relevant codes and did not pose a hazard to personnel or operations.
• Acted decisively to stop any machinery or apparatus presenting a danger to personnel, while ensuring the provisions of the Act and regulations were fully enforced and adhered to by all teams under my supervision.
• Executed all statutory responsibilities aligned to Regulation 2.13.4.1, including ensuring work was carried out by trained, competent persons and adhering to the engineering appointment’s obligations in general charge of machinery.

Maintenance Management

• Developed and executed a targeted preventative maintenance strategy for high-impact rotating equipment—including bucket elevators—across all MSP products sections, with the objective of reducing unplanned downtime and improving plant availability.
• Led cross-functional alignment of maintenance teams, fostering collaboration across three product areas to ensure consistent execution standards, shared ownership of outcomes, and optimal use of available technical expertise.
• Led the full implementation of the work management process, ensuring structured planning, prioritisation, scheduling, execution, and close-out of all maintenance activities—forming the backbone of reliable and repeatable performance.
• Aligned and unified resources across three MSP products sections, coaching teams to collaborate effectively, apply consistent standards, and leverage collective expertise to eliminate rework and meet planned outage commitments.
• Fostered a culture of accountability and continuous improvement, mentoring team members to adopt a proactive, system-driven maintenance mindset—resulting in reduced off-cycle standby call-outs, improved equipment reliability, and greater maintenance execution discipline.

Equipment and Process Omptimisation

• Led the optimisation and configuration of critical separation equipment including high-tension roll separators (HTRS), electrostatic plate separators (ESPs), and magnetic separators, to ensure safe and reliable operation in a high-demand mineral processing environment.
• Established robust operating parameters to prevent equipment damage caused by rapid transient electrical surges resulting from air dielectric breakdowns, enhancing overall electrical system integrity and equipment lifespan.
• Reduced process dependency on the Smoker circuit by improving the efficiency and consistency of mineral separation within dry circuits, contributing to a more stable and predictable production process.
• Mitigated fire risk associated with Smoker circuit operation through proactive process redesign and improved equipment reliability, directly supporting plant safety and compliance goals.
• Collaborated cross-functionally with electrical, mechanical, and processing teams to integrate best practices in condition monitoring and preventative maintenance strategies.
• Demonstrated strong leadership and technical decision-making by balancing production targets, safety considerations, and asset management priorities to deliver sustainable engineering solutions aligned with business objectives.

Water Management

• Led the implementation of flow measurement instrumentation along the MPOSA pipeline, a high-value water supply line to the SP&L area, enabling real-time detection of leaks and immediate response coordination.
• Strategically prioritised the MPOSA pipeline for continuous monitoring, recognising its elevated operational cost compared to other water sources at Richards Bay Minerals, and aligning maintenance focus with risk and value drivers.
• Introduced a monitoring system based on flow rate differentials between inlet and outlet points, allowing for precise leak quantification and enabling data-driven decisions on intervention type and urgency.
• Improved water loss control and operational reliability, embedding a proactive maintenance culture and enhancing the team’s responsiveness to infrastructure risks with minimal environmental and production impact.

Central Maintenance Workshop Management

• Led the optimisation of planning and execution processes within the Central Maintenance Workshop, aligning daily activities with production priorities and improving overall coordination across disciplines.
• Introduced and championed resource leveling techniques to balance workloads, optimise manpower utilisation, and eliminate workflow bottlenecks—enhancing the predictability and efficiency of maintenance operations.
• Implemented a structured work assessment framework, evaluating tasks based on complexity, criticality, and turnaround time, which enabled data-informed decisions on in-house execution versus outsourcing.
• Improved maintenance turnaround times and asset readiness, while ensuring effective utilisation of internal skills and fostering a culture of continuous improvement in planning and maintenance execution.

Complex Critical Infrastructure Repairs

• Directed the successful execution of a high-complexity pipeline repair on the Monzi line, a key water supply to Mining Pond Echo, where the affected section could only be accessed via water. Oversaw all logistical and technical planning to ensure safe and effective execution.
• Led multi-stakeholder collaboration, engaging with local communities and adjacent sugarcane farmers to secure access rights and foster cooperation—demonstrating diplomacy, influence, and community relationship management.
• Mobilised specialised equipment and resources to perform the repair under physically and environmentally constrained conditions, while maintaining full alignment with HSE standards, site risk protocols, and procurement governance.
• Strengthened water infrastructure resilience under critical operational conditions, while reinforcing safety culture, environmental stewardship, and engineering excellence in the face of non-standard challenges.

Statutory Engineering Responsibility (MAR Reg. 2.13.3.1)

Legally appointed engineer in general charge of machinery, accountable for the safe installation, operation, and maintenance of all machinery, structures, and tanks. Ensured compliance with MHSA, SANS, and international standards through audits, inspections, and corrective action management. Maintained all safety devices in working order and stopped unsafe equipment use. Fulfilled all duties under Reg. 2.13.4.1, ensuring work was executed by competent persons.

Change Management:

• Led the change management process for plant improvement initiatives, developing risk-assessed scopes of work to ensure safe, compliant, and effective implementation of technical modifications.
• Drove engineering changes to eliminate high-risk hazards, including redesigning structures to mitigate fall-from-height and entanglement risks, interlocking conveyor guards, and isolating hydraulic pressure on a static rock breaker to reduce crushing risk.
• Achieved a 47% reduction in water consumption in the secondary ore crushing and screening plant by modifying the thickener water recovery system—improving operational efficiency and sustainability.
• Conducted Root Cause Failure Analyses (RCFA) to support defect elimination, resulting in strategic equipment improvements such as:
• Replacement strategy for the primary double toggle Blake-type jaw crusher pitman shaft
• Enhanced lubrication system for secondary gyratory cone crushers
• Redesign of 24VDC safety circuit systems on conveyors to improve system reliability and personnel safety

Maintenance KPI Management

• Championed leading maintenance KPIs across both permanent and contractor teams to drive accountability and performance during scheduled weekly and extended plant maintenance shutdowns.
• Ensured safe, on-time completion of planned work through rigorous planning, field verification of inspection findings, and prioritisation of corrective actions aligned to asset criticality.
• Standardised maintenance work procedures and monitored actual task durations across team members to identify safe opportunities for cycle time reduction, improve predictability, and embed a culture of continuous improvement.
• Developed robust critical spares strategies to minimise unplanned downtime risks, while proactively addressing skill gaps through structured assessments and targeted remedial training for individuals requiring upskilling.

Financial Control and Budget Management:

• Managed the financial planning and control of plant and equipment maintenance, including budget forecasting, expenditure monitoring, and cost allocation to ensure effective resource utilisation and compliance with financial targets.
• Scrutinised quotations for external goods and services, balancing technical needs with commercial value to optimise spend without compromising service levels or maintenance quality.
• Performed detailed cost analysis using SAP ERP and master data, enabling transparent tracking and verification of maintenance spend across cost centres.
• Identified a critical pricing error in SAP resulting in a payment two orders of magnitude above the actual value, initiated recovery actions, and ensured the surplus was successfully returned to the business—demonstrating diligence in financial governance.

Team Management and Performance:

• Provided strategic leadership to the maintenance team, cultivating a high-performance culture rooted in accountability, ownership, and aligned execution of the business plan.
• Applied LEAN principles with a strong focus on the bottom-up approach, empowering frontline personnel to identify improvement opportunities, streamline processes, and eliminate inefficiencies.
• Promoted cross-functional collaboration and continuous improvement, aligning the team behind shared objectives and fostering an environment where innovation and proactive problem-solving were encouraged.
• Conducted regular performance evaluations and coaching sessions, offering constructive feedback and development support to enhance individual capability and collective productivity, resulting in a motivated workforce driven by purpose and shared success.

Safety Compliance

Led the oversight of multiple mining projects, ensuring strict adherence to safety standards and regulations set forth by the Mine Health & Safety Act. Implemented robust safety protocols and procedures, resulting in zero lost-time injuries across all maintenance activities under my supervision. Constructed a brake test area for Utility vehicles in conformance to SANS 1589 to guarantee proper operation all braking systems on each utility vehicle.

Cross-functional Collaboration for Production Optimization

• Collaborated with cross-disciplinary teams including geologists, mining engineers, and environmental specialists to align maintenance strategies with production goals, minimise disruptions, and strengthen the link between asset integrity and operational performance.
• Facilitated structured production and maintenance review meetings, using real-time data to identify equipment-related bottlenecks and implement targeted corrective actions to enhance availability, safety, and efficiency.
• Installed Tyre Pressure Monitoring Systems (TPMS) on primary load and haul equipment to eliminate daily manual pressure checks, reducing shift delays and preventing premature tyre failures from over- or under-inflation.
• Improved mobile equipment availability and tyre asset reliability as part of the broader asset integrity strategy, ensuring consistent operating conditions, extended component life, and reduced unscheduled maintenance events.

Contracts Management

• Led the development of a comprehensive project scope for the rental and maintenance of diesel locomotives, aligned to the operational needs of the loadout station and compliant with the train loading schedule.
• Applied structured project management principles, including stakeholder engagement, scope definition, resource planning, and risk mitigation to ensure safe, reliable locomotive availability for continuous operation.
• Oversaw technical evaluations of service providers, ensuring the selection of high-performing partners with proven capability to deliver efficient maintenance support and operational uptime.
• Embedded support mechanisms into the project plan, including:
• Resourcing strategies for planned and standby maintenance teams during live train loading
• Provision of technical documentation and basic OEM training for permanent staff
• Onsite and offsite maintenance infrastructure
• Critical spares strategies and secure storage solutions to support lifecycle reliability

Training and Mentorship

• Provided mentorship and technical leadership to artisans and vehicle systems technicians, fostering a high-performance culture focused on accountability, growth, and operational excellence.
• Promoted continuous professional development by coaching team members on diagnostics, systems thinking, and problem-solving aligned with equipment and operational demands.
• Led regular training and knowledge-sharing sessions on critical safety protocols, equipment operation, emergency preparedness, and mining best practices to reinforce a culture of safety and technical discipline.
• Built team confidence and capability through purposeful engagement, aligning individual development plans with business objectives and strengthening bench strength for future operational demands.

Ensuring Safety Compliance and Team Protection

• Enforced rigorous safety standards and procedures, ensuring full compliance with the Mine Health and Safety Act Regulations to protect personnel from operational hazards.
• Led routine safety inspections and audits, proactively identifying and addressing risks to maintain a safe and legally compliant working environment.
• Embedded a culture of safety accountability, promoting consistent adherence to protocols and empowering team members to prioritise safe behaviors in all activities.

Training and Mentoring for Knowledge Enhancement

• Facilitated structured training programs and skills development plans to ensure technical competency and operational readiness across all maintenance personnel.
• Provided close mentorship to new and less experienced team members, accelerating onboarding, reducing knowledge gaps, and enhancing team performance.
• Promoted a culture of continuous learning and capability growth, aligning development initiatives with business needs and maintenance excellence standards.

Technical Documentation Review and Maintenance Execution

• Reviewed and validated technical documentation to ensure maintenance and repair activities aligned with OEM specifications and industry best practices, supporting equipment reliability and safety.
• Supervised and actively participated in key maintenance interventions, ensuring efficient task execution, quality workmanship, and reduced equipment downtime.
• Maintained accurate records of statutory inspections and maintenance, enabling effective Root Cause Failure Analyses (RCFAs) and supporting incident investigations and compliance audits.

Task Prioritization

• Monitored maintenance task priorities and ensured clear communication between teams and management, aligning daily activities with broader organisational goals and operational demands.
• Strategically delegated responsibilities across the team, optimising workflow efficiency and driving the timely, effective completion of maintenance activities.

Daily Operations Supervision and Performance Management:

• Supervised day-to-day maintenance operations, ensuring effective execution of preventive maintenance tasks, adherence to safety protocols, and consistent team performance.
• Conducted regular performance evaluations and provided targeted feedback, driving continuous improvement in productivity, accountability, and team effectiveness.

Cost-Effective Procurement and Vendor Management:

• Sourced and evaluated vendor proposals to ensure cost-effective procurement of materials and equipment, negotiating favourable terms, supporting CAPEX/OPEX control, and maintaining strong supplier relationships.
• Implemented strategic procurement and inventory management practices to optimise resource utilisation, minimise stockholding costs, and enhance overall operational and maintenance efficiency.

Gained Proficiency in Mining Machinery

Developed expertise in mining machinery encompassing design, operation, maintenance, and health and safety standards, aligning with the requirements of Mine Engineers Certificate of Competency (GCC) Electrical Engineer-in-Training.

Collaborated with Engineering Teams

Engaged with engineers and OEMs to investigate and address equipment failure issues, contributing to effective problem-solving and resolution implementation. Participated in collaborative discussions to identify root causes and devise practical solutions for maintenance and operational challenges.

Performed Basic Maintenance Activities

Safely participated in the execution of critical maintenance activities in adherence to established protocols and safety procedures. Demonstrated proficiency in executing maintenance tasks efficiently and effectively, contributing to the smooth operation of mining machinery and equipment while gaining crucial knowledge and experience aligned with my career goals.