Millwright

Position Overview:

We are seeking a highly skilled and experienced Millwright to join our team. The successful candidate will be responsible for the installation, maintenance, troubleshooting, and repair of industrial machinery and mechanical equipment within the cable manufacturing plant. The role ensures optimal performance of equipment, adherence to safety and quality standards, and continuous improvement to support efficient production.

Core Activities:

• Preventive & Predictive Maintenance: 

Inspect mechanical and electrical systems according to scheduled plans. Lubricate and replace worn parts to prevent breakdowns.  Use diagnostic tools (vibration analyzers, thermal cameras, ultrasonic sensors) to monitor equipment condition.  Maintain maintenance logs and adjust maintenance frequency based on equipment history.

• Troubleshooting & Breakdown Response: 

Rapidly assess machinery that has stopped functioning and diagnose the root cause.  Perform mechanical and electrical repairs such as bearing replacements, motor testing, gear adjustments, and electrical fault isolation.  Replace or recondition faulty components to restore production.  Prioritize breakdowns based on impact to production schedules and escalate when needed.

• Machine Installation, Commissioning & Upgrades:

Assemble and install new mechanical/electrical equipment (extruders, pullers, winders, etc.).  Align shafts, couplings, and pulleys using laser alignment tools or dial indicators.  Verify electrical connections and integrate machines into power and control systems.  Conduct dry runs and performance testing before handing over to production.

• Calibration, Setup & Adjustments: 

Calibrate machinery components such as tension rollers, motor speeds, cutting lengths, and feed rates for consistent cable quality.  Fine-tune sensors, encoders, and actuators to meet quality and productivity standards.  Adjust PLC settings or assist with HMI parameter tuning where required (if multi-skilled). 

• Safety Inspections & Compliance Enforcement: 

Inspect guards, interlocks, emergency stops, and electrical panels regularly.  Apply Lockout/Tagout (LOTO) before maintenance.  Ensure all repairs and installations comply with OHS regulations and company safety procedures.  Participate in toolbox talks and risk assessments.

• Collaboration with Operations, Engineering & Quality: 

Work with production to understand recurring machine issues and performance bottlenecks.  Coordinate with engineers on equipment modifications or redesigns.  Support quality assurance by ensuring equipment supports consistent output (e.g., tension control, insulation thickness).  Assist with training junior technicians or apprentices on standard maintenance.

Core Decisions:

• Maintenance Timing Decisions: 

When to perform preventive vs. corrective maintenance Assess equipment condition and history to determine if it can run until the next scheduled service or requires immediate attention.  Whether to take machinery offline for repair or wait for production downtime.  Balance production urgency against risk of extended damage or safety concerns.

• Fault Diagnosis and Repair Decisions: 

How to isolate and identify root cause of a machine malfunction.  Decide between mechanical, electrical, pneumatic, or control system failure paths. What repair method or component to use.  Choose between repairing a part, replacing it, or modifying the setup temporarily to resume production.

• Installation and Alignment Decisions: 

How to position and align machinery or components during installation.  Decide on tolerances, measurement tools (e.g., laser alignment vs. feeler gauges), and anchoring methods.  When a newly installed machine is ready for production.  Evaluate test results, calibration accuracy, and compliance with operational specs before handover.

• Tool and Technique Selection: 

What tools, lubricants, or materials to use for a specific task.  Select based on OEM specs, machine type, and operating conditions.  Which troubleshooting technique to apply (thermal imaging, vibration analysis, manual inspection).  Based on type of fault symptoms and available diagnostics tools.

• Prioritization and Workflow Management: 

Which breakdown or maintenance task to attend to first.  Based on severity, impact on production, and availability of resources.  When to escalate an issue to engineering, supervision, or OEM support.  Decide when a problem exceeds skill or authority level.

• Collaboration and Communication: 

What information to share with production, engineering, or quality.  Decide what's relevant for minimizing misunderstandings and optimizing machine performance.  When to involve electricians, technicians, or shift supervisors for joint tasks.  Coordinate based on skill requirements, safety, and task complexity.

Core Capabilities:

• Mechanical Repair & Assembly Expertise: 

Ability to dismantle, repair, and reassemble machines such as extruders, winders, pullers, and cutters.  Familiar with shafts, bearings, couplings, gearboxes, pulleys, and chain drives.  Skilled in setting tolerances, torque levels, and alignment for optimal machine function.

• Electrical and Electro-Mechanical Competency: 

Understanding of motors (AC/DC), sensors, relays, contactors, and motor control circuits. Capable of performing continuity checks, insulation resistance tests, and motor rewiring.  Basic knowledge of electrical panels, wiring diagrams, and programmable logic controllers (PLCs).

• Precision Alignment & Calibration Skills: 

Use of tools like dial indicators, feeler gauges, laser alignment systems, and spirit levels.  Able to calibrate machines for speed, pressure, tension, and temperature settings specific to cable production.  Sets mechanical limit switches, photo eyes, and proximity sensors accurately.

• Diagnostic & Fault-Finding Ability:

Rapid root cause analysis of breakdowns through sound, vibration, and performance symptoms.  Use of diagnostic equipment (vibration meters, thermal cameras, multimeters). Ability to distinguish between mechanical, electrical, and pneumatic faults.

• Preventive & Predictive Maintenance Knowledge:

Implementation of routine inspections, lubrication, and part replacement.  Familiar with predictive technologies (vibration, thermography, oil analysis).  Maintains and updates maintenance schedules using CMMS (Computerized Maintenance Management Systems).

• Tool and Equipment Handling:

Skilled in use of hand tools, power tools, welding/brazing equipment, grinders, and hydraulic presses.  Proper storage, maintenance, and calibration of tools.

Requirements:

• Grade 12 or equivalent. Completed and accredited Millwright Certificate/Trade Test.
• Qualified forklift/crane operator (advantageous). Valid Code 08 Driver's Licence.
• Minimum 3 years of proven experience as a Millwright in a heavy industrial or manufacturing environment.
• Preferably experience within cable production or electrical wire manufacturing sectors.
• Strong technical knowledge of mechanical systems, motors, drives, conveyors, and safety systems.
• Demonstrated ability to work safely in high-risk and high output environments
• Strong mechanical and electrical troubleshooting skills.
• Ability to perform under pressure and deliver within deadlines.
• Team collaboration with internal departments (Production, Engineering, SHEQ).
• Sound knowledge of Health, Safety, Environment, and Quality (SHEQ) principles.
• Accurate documentation and reporting.
• Excellent analytical and problem-solving skills.
• Good persuasion and influencing abilities.
• Adaptability to changing technologies and manufacturing trends.
• Proficient in planning and organizing technical work.