Job Description

Roles & Responsibilities

• Major Hazard Governance

  • Establish and maintain an enterprise-wide Major Hazard Risk Management Framework.

  • Define, implement, and oversee Critical Controls for major hazard exposures, including:

    • Molten metal handling and transfer operations.

    • Potline integrity and high-voltage electrical systems.

    • Gas systems (e.g., natural gas, hydrogen, and compressed gases).

    • Pressure systems and stored energy hazards.

    • Confined space entry and other high-risk activities.

  • Ensure governance and control frameworks are aligned with recognized international standards and industry best practices, including:

    • International Council on Mining and Metals (ICMM) Critical Control Management Guidance.

    • Center for Chemical Process Safety (CCPS) Risk-Based Process Safety Framework.

    • Occupational Safety and Health Administration (OSHA) Process Safety Management (PSM) Principles.

  Fatality & Serious Injury Prevention (SIF Focus)

  • Lead the strategic shift from traditional lagging safety metrics (TRIFR/LTIFR) toward Serious Injury and Fatality (SIF) prevention, ensuring the organization prioritizes catastrophic risk exposure and Major Accident Event (MAE) prevention.

  • Establish and govern a robust SIF and High Potential (HiPo) Event Framework, including:

    • Clear definitions.

    • Classification criteria.

    • Escalation thresholds.

  • Monitor and report barrier health and Critical Control effectiveness by:

    • Detecting control degradation.

    • Monitoring overdue verification activities.

    • Identifying weak signals.

    • Detecting operational drift.

  • Ensure all High Potential events, Critical Control failures, and recurring systemic weaknesses are reviewed with the Executive Committee, including:

    • Credible worst-case outcomes.

    • Failed or degraded controls.

    • Immediate corrective actions.

    • Long-term systemic improvements.

  • Implement and oversee an independent verification program for Life-Saving Rules and Critical Controls by ensuring high-risk controls are:

    • Tested against defined performance standards.

    • Verified through field validation and evidence-based assurance.

    • Tracked through governance dashboards.

    • Escalated when non-compliant or ineffective.

  • Ensure leadership accountability through:

    • SIF performance reviews.

    • Barrier assurance reporting.

    • Board-level visibility of major hazard exposure and Critical Control performance.

  Engineering & Asset Integrity

  • Provide governance and oversight of engineering systems that protect against major hazards, including:

    • Mechanical Integrity Programs.

    • Electrical Integrity and Arc Flash Risk Controls.

    • Management of Change (MOC) Governance.

    • Safe Design Reviews for new smelter technologies and modifications.

  • Ensure Process Safety requirements are embedded into all capital projects, expansions, and major upgrades from concept through commissioning and operational handover.

  Automation & AI in Process Safety

  • Lead the integration of advanced technologies to strengthen Process Safety performance and reduce catastrophic risk exposure, including:

    • AI-based predictive analytics for early anomaly detection and emerging risk trends.

    • Real-time monitoring of critical parameters such as temperature, pressure, and gas concentrations.

    • Smart sensors for molten metal transport systems and other high-risk equipment.

    • Digital barrier management and Critical Control verification platforms.

    • Automated shutdown and interlock systems to eliminate or minimize human exposure.

  • Ensure digital and automation initiatives align with Serious Injury and Fatality (SIF) prevention principles and National Safety Council leading practices.

  Board Reporting & Risk Transparency

  • Provide quarterly Board-level reporting on key Process Safety and Major Hazard indicators, including:

    • Tier 1 and Tier 2 Process Safety Events.

    • Critical Control Effectiveness Rate.

    • Barrier Health Index.

    • High Potential Incident (HiPo) Trends.

    • Mechanical Integrity Backlog and Risk Exposure.

    • Major Hazard Risk Heat Map.

  • Ensure the Board has timely visibility of:

    • Catastrophic risk exposure.

    • Emerging threats.

    • Effectiveness of mitigation measures.

    • Critical Control performance.

  Authority & Decision Making

  Authority

  • Authorized to stop or suspend high-risk operations, including:

    • Molten metal transfer.

    • High-voltage electrical work.

    • Gas system activities.

    • Confined space entry.

    • Major lifting operations.

  • Approve and enforce Critical Control Performance Standards, including verification frequencies, assurance methodologies, and minimum compliance thresholds.

  • Require immediate corrective actions and establish risk-based deadlines where major hazard exposure is elevated or Critical Controls are failing.

  • Approve or reject Management of Change (MOC) outcomes for modifications affecting:

    • Processes.

    • Equipment.

    • Technology.

    • Procedures.

    • Operating conditions.

  • Challenge operational decisions and require revalidation of risk assessments where:

    • Hazard studies are incomplete, outdated, or poorly scoped.

    • Critical Controls are not clearly defined.

    • Residual risk is not within acceptable or tolerable limits.

  Decision Making

  • Identify critical factors affecting major hazard risks and operational safety.

  • Evaluate alternatives and establish priorities based on risk exposure.

  • Anticipate potential outcomes and assess operational consequences.

  • Make informed decisions under conditions of uncertainty and elevated risk.

  • Apply sound engineering judgment, quantitative analysis, and risk-based decision-making principles to protect people, assets, environment, and business continuity.

Desired Candidate Profile

• Bachelor's Degree in Engineering (Chemical, Mechanical, Electrical, Process Engineering, or a related discipline).

• Minimum 15 years of experience in high-hazard industrial operations.

• Demonstrated expertise in:

  • Hazard and Operability Studies (HAZOP).

  • Layers of Protection Analysis (LOPA).

  • Bowtie Risk Analysis.

  • Critical Control Management (CCM).

  • Major Accident Prevention.

  • Regulatory engagement and Board Committee reporting.

  • Digital technologies, data analytics, and Process Safety systems.

Leadership Expectations

• Demonstrates the independence and authority to escalate catastrophic risk concerns to Executive Management and the Board.

• Exercises the judgment and decisiveness to stop unsafe, high-risk operations when Critical Controls are ineffective or degraded.

• Applies systems-thinking principles to identify root causes, systemic weaknesses, and cross-functional risk interactions.

• Influences senior leadership and operational teams to strengthen Process Safety culture, governance, accountability, and continuous improvement.

• Promotes a proactive approach to catastrophic risk prevention through visible leadership and effective decision-making.

Key Performance Indicators (Board-Level)

• Zero Tier 1 Catastrophic Process Safety Events.

• ≥95% Critical Control Verification Effectiveness.

• 100% Management of Change (MOC) compliance for all major risk changes.

• Continuous reduction in Serious Injury & Fatality (SIF) potential and High Potential (HiPo) events.

• 100% closure of high-risk corrective actions within agreed target timeframes.

Why This Role is Critical in the Aluminium Industry

• Ensures effective management of major hazards associated with aluminium smelting operations, including:

  • Molten metal handling at temperatures exceeding 700°C.

  • High-amperage electrical systems.

  • Combustible dust hazards.

  • Heavy lifting and crane operations.

• Prevents catastrophic incidents resulting from Critical Control failures, including:

  • Multi-fatality events.

  • Major fires and explosions.

  • Significant asset damage.

  • Business interruption and reputational loss.

• Drives the organization's transition from reactive injury management to proactive catastrophic risk prevention through:

  • Robust Major Hazard Governance.

  • Critical Control Assurance.

  • Risk-based decision-making.

  • Executive and Board-level visibility of Process Safety performance.