Job Openings Crushing & Milling Supervisor

About the job Crushing & Milling Supervisor

Job Purpose

To supervise and coordinate safe, efficient, and reliable operations across the crushing and milling circuits of a zinc processing plant. The Crushing & Milling Supervisor ensures stable ore flow, optimum grinding performance, compliance with safety and metallurgical requirements, and effective leadership of plant operators to meet production targets.

Key Responsibilities

Operational Leadership

Lead all crushing and milling operations during the shift/day.

Supervise:

  • Crushing control room operators
  • Field operators (crushing & milling)
  • ROM/apron feeder operators
  • Mill attendants / cyclone operators
  • Allocate tasks, manage workflow, and oversee operational discipline.

Crushing Plant Oversight

  • Ensure safe and efficient operation of:
  • Primary gyratory crusher
  • ROM bin & rock breaker
  • Apron feeders & scalping screens
  • Primary conveyors & transfer chutes
  • Maintain consistent feed to the milling circuit through stable crushing throughput.

Milling Circuit Oversight

Oversee:

  • SAG/ball mills
  • Mill lubrication systems
  • Cyclone clusters and classification
  • Mill discharge pumps
  • Density control, mill water addition & circulating load
  • Maintain optimum grinding performance for zinc liberation and downstream flotation.

Process Monitoring & Optimisation

Monitor key indicators:

  • Crusher power draw & product size
  • Mill load & power consumption
  • Density, cyclone pressure & split
  • Ore hardness changes
  • Adjust operational parameters and coordinate with metallurgists on optimisation strategies.

Equipment Condition Monitoring

Ensure routine field inspections of:

  • Crusher chamber wear components (mantle, concaves)
  • Feeder chains, motors, and gearboxes
  • Mill liners, trunnions, motors, and bearings
  • Cyclone wear components & pump health
  • Conveyor belts and safety devices
  • Report abnormalities and enforce prompt maintenance intervention.

Breakdown Response & Troubleshooting

  • Take control during equipment failures.
  • Coordinate with maintenance teams on isolations, root cause identification, and safe restarts.
  • Prioritise actions that minimise plant downtime and protect equipment assets.

Safety & Compliance

Enforce compliance with:

  • Mine Health & Safety Act (MHSA)
  • Lock-out/Tag-out procedures
  • Permit-to-work systems
  • Working-at-heights and confined space rules
  • Lead shift safety meetings and conduct safety inspections.

Communication & Coordination

Maintain strong communication with:

  • Upstream, Downstream and Ancillaries Section
  • Metallurgy
  • Maintenance (mechanical, electrical, instrumentation)
  • Control room personnel
  • Production management
  • Ensure smooth handovers between shifts.

Reporting & Documentation

Complete:

  • Shift production reports
  • Downtime and breakdown logs
  • Safety incident reports
  • Inspection sheets
  • Operational logbooks
  • Track crushing and milling KPIs and escalate issues promptly.

Required Skills & Competencies

Technical Competencies

Strong understanding of:

  • Gyratory crushing & ore handling systems
  • Milling circuits (SAG/ball mills, classification, pump systems)
  • SCADA/DCS plant control systems
  • Ore hardness, grind size, and metallurgical interactions
  • Basic mechanical/electrical fault awareness.
  • Leadership Competencies
  • Strong supervisory and communication skills.
  • Ability to make fast, informed decisions under pressure.
  • High safety awareness and enforcement.
  • Capability to mentor and develop operator teams.

Qualifications & Experience

Minimum Requirements

  • Grade 12 (Matric).
  • 5–8 years' experience in crushing, milling, or mineral processing.
  • 2+ years in a supervisory or senior operator role.
  • Knowledge of MHSA, process control systems, and heavy plant operations.

Preferred

  • NQF Level 4 or higher in Mineral Processing / Plant Operations.
  • Experience in zinc, lead, copper, or base metal operations.
  • First Line Management or supervisory certificate.
  • Familiarity with major OEMs (Metso, FLSmidth, Sandvik equipment).

Physical & Work Environment Conditions

  • Work in dusty, noisy, and high‑vibration environments.
  • Must perform regular inspections involving climbing, walking, and accessing plant structures.
  • Rotating shifts, weekends, and overtime required.
  • Must be able to respond rapidly to plant upset conditions.

Key Performance Indicators (KPIs)

  • Crushing and milling throughput.
  • Mill product grind (P80) consistency.
  • Crusher and mill uptime.
  • Safety compliance (zero harm).
  • Reduction of unplanned downtime.
  • Effective shift reporting & communication.
  • Team productivity and training quality.

Housekeeping and equipment care


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