Kevin Gava

Asset Strategy Development:

• Implement Asset Tactics Development (ATD) projects, integrating SAP for the creation of asset master data, PRT Documents and Maintenance Plans, Equipment Tasklist work centers, and functional locations.
• Utilize Arena Simulation Software and Binmak's Production Flow Optimisation module for Theory of Constraints (TOC) applications to enhance production flow and reduce bottlenecks.

SAP Integration and Development:

• Design and build ABAP function modules for remote function calls, facilitating seamless data management including equipment tasklists, maintenance plans, and PRT documents.
• Develop custom functions for extracting and analyzing data from SAP reports (IW29, IW39, IW47, IW69) to evaluate equipment reliability and maintenance activity efficiency.

Risk Management and Compliance:

• Asset Management Maturity Assessment: ISO 55000
• Conduct comprehensive Asset Management Maturity Assessments (AMMA) using Binmak's iQuest software to evaluate maintenance and reliability according to key performance indicators and metrics.

Codes of Practice (COPs) Assessments:

• Carry out assessments for specific Codes of Practice, including Engineering Risk Assessment and Permit to Work System, and Isolation and Lockout of Hazardous Energy.

Spare Parts Management:

• Build functions for analyzing and managing spare parts requirements using SAP modules on BOM, stock overview, maintenance work orders, and Maintenance historical data.

Performance Improvement and Reporting:

• Manage the integration of our asset management platform with SAP, facilitating the automatic extraction and real-time analysis of data from maintenance work orders, schedules, and notifications. This system enables sophisticated data analysis and dashboard reporting, providing dynamic insights into maintenance effectiveness and equipment reliability. Oversee the automated generation of detailed, customizable reports that inform strategic decision-making and ensure compliance with industry standards.

E-learning & Training Development

• Design and deliver digital training combining written documents, video tutorials, and LMS tracking for consistency and compliance.
• Create interactive training content using TalentLMS, Articulate 360, HeyGen, and Synthesia, supporting remote and blended learning delivery.

Applied reliability engineering principles to improve asset performance and production efficiency in plastics manufacturing.

• Conducted Failure Mode and Effects Analysis (FMEA) on key assets (extruders, granulators, shredders) to identify critical failure modes, assess risk, and develop preventive maintenance strategies.
• Align maintenance tactics with operational requirements, ensuring asset availability and cost-effective performance.
• Led defect elimination initiatives, addressing recurring equipment failures through root cause analysis and corrective action plans.
• Implemented asset tactics development for extrusion and granulation equipment, optimizing maintenance intervals and improving reliability KPIs.
• Supported process optimization and debottlenecking projects, linking equipment reliability improvements with production flow efficiency.
• Utilized Acumatica ERP for kit building, production planning, and integration of maintenance data with operations.
• Oversaw raw material logistics (HDPE, LDPE, masterbatch) and stock control, ensuring production continuity and minimal downtime.

Asset Tactics Development (ATD) Project, Anglo-Platinum Polokwane Smelter-SO2 Abatement Plant:

• Develop and implement 1,756 maintenance plans for a diverse array of equipment including electrostatic precipitators, plant compressors, and cooling towers,pumps, impacting over 2,141 maintainable items. My key deliverables included developing primary and secondary maintenance tactics aligned with AA guidelines, assigning necessary spares, labor, and special tools, and creating detailed work packages for SAP PM upload. This project utilized RCM principles and the Rylson8/Orein equipment library to enhance the reliability and efficiency of the SO2 Abatement Plant's operations.

Curriculum Developer, SAAMA-Approved Maintenance Planner's Course, Optimal:

• Collaborated with the TSWANE Institute of Technology to develop a comprehensive maintenance planner's course, which received SAAMA certification. This role involved designing course content that encompasses best practices in maintenance planning and asset management, ensuring alignment with current industry standards and practices.

Production Planning and Reporting:

• Manage and create detailed production plans using SAGE Evolution software to ensure optimal manufacturing efficiency and product availability.
• Generate accurate and timely monthly production reports to track progress, production tonnage and identify areas for improvement.

Machinery and Equipment Maintenance:

• Oversee the regular maintenance and servicing of all workshop machinery, measuring instruments, and lifting equipment to minimize downtime and extend equipment lifespan.
• Ensure compliance with safety standards and regulations for all machinery operations.

Production Line Management:

• Direct the operation of the IBR and corrugated roofing sheets production line, monitoring all aspects of production to guarantee that product specifications and quality standards are consistently achieved.

Quality Assurance and Control:

• Coordinate and lead quality management review meetings to assess compliance with quality standards and implement corrective actions as necessary.
• Develop and maintain a quality assurance framework that supports continuous improvement in production processes.

Maintenance Execution and Planning:

• Conduct routine and preventive maintenance on various mechanical systems such as gold processing mills, jaw crushers, gyratory crushers, barmac crushers, screen vibrators, fans, conveyor belt systems, valves, and pumps.
• Develop and refine maintenance plans based on operational needs and equipment performance, ensuring all activities are scheduled and executed effectively.

Performance Analysis and Optimization:

• Analyze equipment performance data to identify trends and potential issues.
• Recommend and implement optimization strategies to enhance equipment efficiency and reliability.

Root Cause Analysis:

• Perform thorough root cause analysis on equipment breakdowns to prevent future occurrences.
• Document findings and implement changes in maintenance practices based on analysis results.

Resource Planning for Maintenance Activities:

• Assist in resource planning for scheduled shutdowns and planned maintenance activities to ensure efficient use of personnel, tools, and materials.
• Coordinate with various departments to ensure smooth execution of maintenance operations with minimal impact on production.