Senior Crushing Shift Supervisor

Senior Crushing Shift Supervisor

Job Purpose

To lead and supervise all crushing operations during the shift, ensuring safe, efficient, and reliable performance of the primary crushing plant. The Senior Shift Supervisor coordinates control room and field operators, manages process stability, ensures equipment integrity, and supports production goals for downstream zinc processing.

Key Responsibilities

Shift Leadership & Coordination

Take full operational responsibility for the crushing plant during the shift.

Lead a team of operators:

• Control Room Operators
• Field Operators
• ROM / Apron Feeder Operators
• Senior Plant Operators
• Conduct pre‑shift briefings, safety discussions, and task allocations.
• Ensure effective shift handovers and communication between crews.

Crushing Plant Operational Oversight

Oversee operation of:

• Primary gyratory crusher
• ROM bin, dump pocket & rock breaker (if applicable)
• Apron feeders & scalping equipment
• Primary conveyors and transfer chutes
• Ensure stable ore flow, optimal crusher loading, and consistent product size.
• Adjust operational parameters in coordination with control room.

Safety Management

• Enforce compliance with:
• Mine Health & Safety Act (MHSA)
• LOTO procedures
• Permit-to-work systems
• Safe dumping and mobile equipment protocols
• Machine guarding and access control
• Conduct workplace inspections and identify hazards.
• Lead incident response and ensure proper reporting and escalation.

Process Monitoring & Optimisation

• Monitor metallurgical performance indicators (feed rate, crusher power draw, product size).
• Identify bottlenecks and proactively correct process upsets.
• Assist with ore blending and ore type management.
• Work closely with metallurgists to optimise plant performance.

Equipment Condition Monitoring

Ensure operators conduct routine inspections of:

• Crusher lubrication & hydraulic systems
• Feeder chains, pans, and wear components
• Conveyor belts, rollers, skirting & spillage
• Chute blockages, spill points, and screen health
• Report abnormalities and follow up on maintenance actions.

Breakdown Response & Troubleshooting

• Take leadership during breakdowns and stoppages.
• Coordinate safe isolation and restart with electrical & mechanical teams.
• Assist with root cause identification of recurring issues.
• Minimise downtime and ensure structured recovery.

Reporting & Administration

Complete:

• Shift production reports
• Downtime logs
• Safety reports
• Checklists & inspection forms
• Record shift events, deviations, and corrective actions with accuracy.

Required Skills & Competencies

Technical Competencies

Strong understanding of:

• Gyratory crusher mechanics
• ROM bin and apron feeder behaviour
• Conveyor operation & protection systems
• Process control (SCADA/DCS)
• Crushing metallurgy (ore size, hardness, throughput control)
• Ability to diagnose operational issues.

Leadership Competencies

• Strong communication and authority in managing plant operations.
• Able to lead teams and work under pressure.
• Excellent planning and decision-making skills.
• High safety awareness and strong operational discipline.

Qualifications & Experience

Minimum Requirements

• Grade 12 (Matric).
• 5–7 years' experience in crushing or mineral processing operations.
• 2+ years in a senior operator or leadership role.
• Knowledge of MHSA and crushing safety standards.
• Able to work shifts, overtime, and callouts.

Preferred

• NQF Level 4 or higher in Mineral Processing / Plant Operations.
• Experience in zinc, lead, or base metals mining.
• Supervisory or leadership training (e.g., First Line Management).
• Experience with major OEM gyratory crushers (Metso, Sandvik, FLSmidth).