Instrumentation Foreman

Job Purpose

The Instrumentation Foreman is responsible for planning, supervising, and controlling all instrumentation and process control maintenance activities to ensure accurate measurement, stable process control, safe operations, and optimal plant performance across the zinc mining operation, in line with statutory and site requirements.

Key Responsibilities

Safety, Health & Statutory Compliance

• Enforce compliance with Mine Health and Safety legislation, mine standards, and instrumentation regulations.
• Ensure correct application of permit‑to‑work, lock‑out/tag‑out, isolations, and hazardous area requirements.
• Conduct toolbox talks, task risk assessments, and safety audits.
• Ensure statutory inspections, calibrations, and documentation are completed.
• Investigate instrumentation incidents, failures, and near misses and implement corrective actions.

Instrumentation Maintenance Supervision

Supervise execution of:

• Preventive and condition‑based maintenance
• Breakdown and corrective maintenance
• Shutdown and outage instrumentation work

Ensure effective maintenance of:

• Flow, level, pressure, temperature, and density instruments
• Weigh feeders, belt scales, load cells
• pH, ORP, conductivity, and analytical instruments
• Instrument air systems and field cabling
• Verify calibration accuracy and quality of work completed.

Process Control & Plant Support

• Support production by ensuring reliable instrument performance across:
• Crushing, milling, flotation, leaching, and tailings circuits
• Coordinate quick response to instrument failures affecting plant stability.
• Work with control, electrical, and operations teams to resolve process issues.
• Support PLC, SCADA, and DCS systems from an instrumentation perspective (I/O, loops, alarms).

Leadership & Workforce Supervision

• Allocate work and supervise Instrument Technicians, Shift Technicians, and Assistants.
• Supervise contractors performing instrumentation work on site.
• Coach, mentor, and develop team competency.
• Conduct on‑the‑job training and skills assessments.
• Maintain discipline, productivity, and safe work behaviour.

Planning, Scheduling & Administration

Participate in:

• Weekly and shutdown maintenance planning
• Instrument calibration planning and scheduling
• Ensure accurate completion of:
• Job cards and work orders
• Calibration records and instrument histories
• Assist with spares identification and critical instrument inventory.
• Provide feedback on recurring faults and support root cause analysis.

Projects & Continuous Improvement

• Supervise instrumentation aspects of minor capital projects and plant modifications.
• Ensure compliance with P&IDs, loop drawings, and engineering standards.
• Participate in commissioning, loop checking, and plant start‑ups.
• Drive continuous improvement in measurement accuracy and process reliability.

Minimum Qualifications

• Trade Test Certificate – Instrument Mechanician / Instrumentation Technician
• Grade 12 / NQF Level 4
• Valid Instrumentation Authorisation (as per mine requirements)
• Medically fit for mine and shift work

Advantageous

• Supervisory or Foreman Certificate
• National Diploma in Instrumentation or Process Control
• PLC / SCADA / DCS training
• Hazardous area instrumentation certification

Experience Requirements

• 5–8 years instrumentation experience in mining or heavy industry
• 2–3 years experience in a supervisory or senior instrumentation role

Proven experience in:

• Mineral processing plants (zinc advantageous)
• Shift‑based maintenance environments
• Continuous process control systems

Technical Competencies

• Instrument calibration and diagnostics
• Understanding of control loops and field instrumentation
• Reading and interpretation of P&IDs and loop diagrams
• Instrument air and analyser systems
• Basic PLC I/O and alarm troubleshooting
• Use of test and calibration equipment

Behavioural & Leadership Competencies

• Strong safety leadership and accountability
• Effective planning and prioritisation
• Clear communication across shifts and disciplines
• Decisive problem‑solving under pressure
• Team leadership and mentoring ability