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:
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:
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.