Melvyn Siaw

Reviewed downtime delays daily and provided risk management solutions, formulated and monitored the 2-year budget for Fixed Plant Maintenance, monitored work management metrics weekly and addressed gaps, critically audited business-controlled documentation for variances and gaps, created and governed maintenance strategies for frontline maintenance teams, executed maintenance improvement projects for fixed plant assets to increase plant reliability, performed reliability practices: 5 Whys, RCA and FMEA, conducted life cycle asset management which informed the 5-year plan capital portfolio and built rapport across departments and stakeholders to achieve positive business outcomes

My key achievements:

• Led end-to-end implementation of LPDOC system project mitigating 47 hours of Car Dumper downtime consisting of 105 delay counts equating to a production loss of 225 kT or $22.5M USD seen from FY22
• Developed and facilitated correct calibration procedure for Reclaimer load pin which saw an additional throughput uplift of 2kT/h or $0.2M USD/h
• Instated remote access to Car Dumper VVVF drives providing offsite troubleshooting capabilities reducing MTTR by 32 hours equating to a production loss of 153 kT or $15.6M USD
• Conducted critical spares audit on Car Dumper and Dust Collectors and updated stock levels as per OEM recommendations which would reduce MTTR by 16 hours equating to a production loss of 76 kTonnes or $7.6M USD
• Optimised maintenance strategies for Balanced Machines and implemented 128 safety critical device labels allowing execution teams to readily identify and maintain devices according to BHP Safety Critical System Maintenance Plan
• Integrated PLC flushing sequence logic on TLO preventing pipe blockages and MTBF of sump pump by 400%
• Orchestrated Stacker functional safety improvements from installing 4 new in-field striker indicators for safety encoder machine positioning calibration logic, which eliminated 14 hours of downtime equating to $14.6M USD loss
• Led the formulation of 2-year budget for Fixed Plant Maintenance as reliability cost controller and provided monthly monitoring reports on budget cost planned/actuals to senior leadership teams with recommended continuous improvement actions.

Governed plant blueprint changes with adherence to design control procedures, SEPs and WAIO standards, engineer assessed new electrical equipment designed installations in accordance with HSEC, maintainability and sustainability requirements, provided electrical engineering design support to key stakeholders, quality controlled technical and project documents and audited electrical logbook compliance to statutory requirements and legislation

My key achievements:

• Provided electrical engineering support for Car Dumper 1 Mega Shutdown on Positioner 1 and 2, Apron Feeders and Hydraulic Wheel Locks
• Conducted Annual Business-Critical Equipment and Infrastructure Audit for Port Assets and provided direction on 5 identified assets for actioning to Asset GTS
• Coded VBA scripts for Excel Macro to part-automate review process of Electrical Logbooks reducing review time by 60%
• Remediated 18 Motor Control Centre Arc Flash labels to be updated in adherence to BHP WAIO standard for Protective Equipment for Electrical Work
• Liaised extensively with Project Engineers for electrical design install of 2 ablution blocks at Eastern & Western fuel farms respectively.

Monitored HV Inland network performance daily for safety, asset condition, reliability and power quality, identified maintenance and cost improvement opportunities to comply with WAIO standards, assisted writing of switching programs verifying safe sequencing, liaised with HV operators for continuous improvement opportunities and executed improvement projects to HV network eliminating repetitive failures

My key achievements:

• Prepared project reports to stakeholders for installation of 9 MAC PowerStation generator sirens and amber lights
• Identified 200-hour reduction to rectification process of HV assets by implementing changes to statutory maintenance plans of earthing systems for compliance to WAIO standard and AS2067
• Developed commissioning procedure for protection relays to ensure continual N-1 redundancy of power transmission to Newman Township
• Liaised with OEM to rectify incorrect protection relay trip configuration eliminating nuisance trips, increasing network reliability and performance
• Advised stakeholders on remediation plan for 21 identified non-compliant overhead lines post audit of 64 BHP overhead lines for compliance with AS7000
• Formalised the Business Case for the CAPEX replacement of a faulted HV feeder cable, uncompliant streetlights, and obsolete power quality analyser.

• Conducted analysis for infrastructure and instrumentation assets identifying $200,000 in OPEX savings, reduction of downtime by 50 hours and mitigating discrepancies between planned and actual work by 52%
• Directed an Internal Assurance Audit for 3000 Mining Area C Inactive and Unstarted plans for site maintenance opportunities and alignment to amended Shutdown frequency schedule
• Provided electrical engineering support for Reclaimer End of Line lube upgrade systems for operation monitoring of hydraulic luff cylinder lube systems on CITECT SCADA
• Developed maintenance plans and work instructions for assets: Dust Collectors, On-Belt Analysers, Hoppers and Chutes.