Nkosinathi Zulu
Cato Ridge
Summary
Maintenance Planner with extensive experience in budget management and compliance at BHP Billiton and Assmang Cato Ridge. Executed preventative maintenance projects that significantly enhanced operational efficiency and equipment performance. Proficient in data analysis and project coordination, resulting in reduced downtime and improved operational continuity. Skilled Millwright with expertise in machinery installation, maintenance, and repair, driving increased machinery uptime through effective maintenance strategies.
Overview
23
23
years of professional experience
Work History
Maintenance Planner
Assmang Cato Ridge
Cato Ridge
04.2020 - Current
- Compiled detailed reports on machinery conditions after repairs and service completions.
- Executed preventative and corrective maintenance projects to optimize equipment performance.
- Planned shutdowns to enhance operational efficiency, developing model work orders for sections.
- Prepared budget reports tracking expenditures and forecasting plant availability.
- Created bill of materials for assigned sections to ensure accurate inventory management.
- Generated weekly reports and statutory updates on lifting equipment compliance.
- Expedited spare parts procurement processes and drafted scopes of work for onsite contractors.
- Ensured compliance with health and safety standards for all onsite contractors.
Technician
Freys Food Brend
05.2015 - 03.2020
- Executed maintenance repairs on 12-ton boilers to ensure optimal performance.
- Serviced 11 kV transformers and switch gears to maintain system reliability.
- Conducted routine maintenance on slaughter line components, including gearboxes and drive chains.
- Performed maintenance on chillers operating between -30°C to 5°C in ammonia plant.
- Maintained packaging lines, focusing on Multivac, Gurnther injection, and Smoker boxer systems.
- Acted as manager for one year overseeing slaughter and effluent plants, including chillers.
- Led efforts to minimize downtime through proactive equipment maintenance and repairs.
- Coordinated with team members to streamline maintenance processes across various systems.
HT Millwright
Assmang Manganese – Cato Ridge Works
08.2010 - 04.2015
- Conducted routine maintenance on 33KV transformers and capacitors to ensure optimal performance.
- Serviced 11KV transformers and performed fault finding on electrical panels.
- Installed Neutral Earth Resistors for 11KV transformer protection circuits.
- Executed overhauls on gearboxes, fluid drives, and centrifugal pumps.
- Maintained 40-ton overhead cranes, ensuring operational reliability.
- Performed regular maintenance on air compressors and conveyor belts.
- Addressed breakdowns promptly to minimize downtime.
- Installed Siemens Simacodes and Drives to enhance equipment functionality.
Electrician (FMCG PLANT)
Cipla Medpro Pharmaceuticals
04.2009 - 07.2010
- Executed maintenance and fault finding on powder sachets and liquid filling machines.
- Conducted repairs on high-speed packing and capsuling machines to ensure operational efficiency.
- Managed HVAC systems, including maintenance on boilers and RO water plant.
- Oversaw quality control requirements for new machinery to meet industry standards.
- Coordinated availability of machinery and equipment to optimize production schedules.
- Performed maintenance on wrapping, labeling, and blending machines to enhance reliability.
- Controlled customer orders to ensure timely fulfillment and satisfaction.
Maintenance Supervisor
BHP Billiton
Richardsbay
05.2008 - 03.2009
- Managed operations for two Inductor Holding Furnaces and 4x40 tons crane.
- Supervised extrusion stands mill, ensuring efficient production processes.
- Led a team of nine Millwrights/Fitters, one Boilermaker, two Instrument Mechanicians, and two Apprentices.
- Administered PM system and conducted capacity planning using SAP.
- Processed Purchase Requisitions and Shut Works orders for operational continuity.
- Orchestrated shut planning and managed reservations for spare parts.
- Controlled budget expenditures and forecasted costs to optimize resources.
- Ensured compliance with safety standards throughout the plant.
Shift Supervisor
BHP Billiton
Richardsbay
01.2007 - 04.2008
- Managed five shift millwrights to ensure efficient operations and maintenance.
- Oversaw switching operations for 33KV Pot Room lines to maintain production flow.
- Addressed breakdowns on 33KV Rectifier Transformers for Pot lines to minimize downtime.
- Resolved mechanical issues across eight plant operations within Bayside to enhance reliability.
- Administered preventive maintenance system to optimize equipment performance.
- Conducted capacity planning on SAP for artisan scheduling and resource allocation.
- Processed requisitions for load purchases and shut works orders to meet operational needs.
- Ensured adherence to safety protocols, enhancing overall plant safety standards.
Maintenance Millwright
BHP Billiton
Richardsbay
01.2006 - 01.2007
- Executed planned maintenance and breakdown repairs on various equipment, including variable speed drives and PLCs.
- Configured parameters and installed Yaskawa, Altivar, ABB, and Allen Bradley systems.
- Conducted fault-finding for SCADA systems, ensuring operational efficiency.
- Managed change requests to SCADA interfaces for improved functionality.
- Performed calibration of burner systems and metal level controllers in alloy casting processes.
- Oversaw operation and maintenance of overhead cranes and direct casting machines.
- Led safety audits and task observations to ensure compliance with OSH Act responsibilities.
- Implemented Six Sigma projects to enhance business excellence and reduce failures in pneumatic cylinders.
Millwright Apprenticeship
Tongaat Huletts Suger Mill
Stanger
05.2002 - 06.2005
- Executed electrical panel wiring to optimize machinery performance.
- Serviced steam turbines to enhance energy generation efficiency.
- Maintained centrifugal batching plant for uninterrupted production.
- Conducted maintenance on ID and FD fans to ensure system reliability.
- Overhauled pumps and gearboxes, extending overall equipment lifespan.
- Performed wiring of slip ring motors and control panels to boost operational efficiency.
- Managed overhead crane operations, maintaining safety and compliance standards.
Education
Millwright Apprenticeship -
Tongaat Huletts Suger Mill
Darnall06.2005
N3 - Electro-mechanic’s
Lower Tugela Collage
Mandini01.2004
Matriculated -
ML Sultan Secondary
Stanger01.2000
Some College (No Degree) - Millwright
Shukela Training Centre
DurbanSome College (No Degree) - Medium volts switching
Onsite Training By The Accredited Assessor
DurbanSkills
- Preventative maintenance
- Budget management
- Compliance oversight
- Inventory control
- Project coordination
- Budget preparation
- Compliance management
- Project management
- Data analysis
- Team leadership
- Asset management
- Maintenance scheduling
Further Training
- SIEMENS – SIMOCODE Training
- Medium to High voltage training
- 33kv & 11KV and Spiking Gun Authorized
- Variable speed drive training
- Lifting Machine Inspector
- Overhead pendant crane 42t driver
- Confined Space Examiner Accreditation
- Lock, Test, and Tag Accreditation
- Blitz observer – Safety
- SAPGA – Sasol gas training
Personal Hobbies
Soccer/Fishing
Trade
Millwright
Additional Phone
- 0712349358
- 0671662475
Languages
- English
- IsiZulu
References
- Brendon Dawenaar, HT FOREMAN – ACC Australia, +61472675799
- Ash Bhudia, Plant Engineer (Assmang Cato Ridge) South African Rainbow Minerals, 0824580618
Recognitions Awards
- Recognition Award, From Cast house Manager during extended Power Outage at Bayside, 12/14/08
- Letter of Thanks, From Bayside General Manager during Extended Power Outage at Bayside, 12/14/08
- Recognition Award, For assistance during pipe replacement project in Casthouse Basement
- Recognition Award, For Water Plant Innovations
Personal Information
- ID Number: 8205285358088
- Age: 42
- Health Status: Excellent
- Title: HT Millwright
- Nationality: South African Citizen
- Marital Status: Married
- Place of Birth: Eshowe
Timeline
Maintenance Planner
Assmang Cato Ridge
04.2020 - Current
Technician
Freys Food Brend
05.2015 - 03.2020
HT Millwright
Assmang Manganese – Cato Ridge Works
08.2010 - 04.2015
Electrician (FMCG PLANT)
Cipla Medpro Pharmaceuticals
04.2009 - 07.2010
Maintenance Supervisor
BHP Billiton
05.2008 - 03.2009
Shift Supervisor
BHP Billiton
01.2007 - 04.2008
Maintenance Millwright
BHP Billiton
01.2006 - 01.2007
Millwright Apprenticeship
Tongaat Huletts Suger Mill
05.2002 - 06.2005
Millwright Apprenticeship -
Tongaat Huletts Suger Mill
N3 - Electro-mechanic’s
Lower Tugela Collage
Matriculated -
ML Sultan Secondary
Some College (No Degree) - Millwright
Shukela Training Centre
Some College (No Degree) - Medium volts switching
Onsite Training By The Accredited Assessor
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