Requirements
Requires an Engineering degree (Chemical, Mechanical, Electrical, or Process) and 15+ years of experience in high-hazard industrial operations. Deep expertise in HAZOP, LOPA, Bowtie, Critical Control Management, Major Accident Prevention, engaging regulators and Board committees, and strong digital and data analytics literacy are essential.
Description
Job description:JOB PURPOSE:The Process Safety Director is accountable for preventing catastrophic events, including molten metal explosions, high-energy electrical incidents, structural failures, toxic gas releases, and major fires.The role ensures that major hazard risks are systematically identified, controlled, verified, and reported to Executive Management and the Board.This position safeguards people, assets, reputation, and business continuity by strengthening governance, assurance, and operational discipline across all major hazard activities.STRATEGIC ACCOUNTABILITIESMajor Hazard Governance Establish and maintain an enterprise-wide Major Hazard Risk Management Framework. Define, implement, and oversee Critical Controls for major hazard exposures, including:o Molten metal handling and transfer operationso Potline integrity and high-voltage electrical systemso Gas systems (e.g., natural gas, hydrogen, compressed gases)o Pressure systems and stored energy hazardso Confined space entry and associated high-risk activities Ensure governance and control frameworks are aligned with recognized international standards and best practice, including:o International Council on Mining and Metals Critical Control Management guidanceo Center for Chemical Process Safety Risk-Based Process Safety frameworko Occupational Safety and Health Administration PSM principles Fatality . 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, and escalation thresholds to ensure consistent identification and reporting of events with fatality potential Monitor and report barrier health and Critical Control effectiveness, ensuring early detection of control degradation, overdue verification activities, weak signals, and operational drift. Ensure all high-potential events, critical control failures, and repeated systemic weaknesses are reviewed directly with the committee, including clear summaries of:o credible worst-case outcomeso failed or degraded controlso immediate corrective actionso long-term systemic improvements Implement and oversee an independent verification program for Life-Saving Rules and Critical Controls, ensuring that high-risk controls are:o tested against defined performance standardso verified through field validation and evidence-based assuranceo tracked through governance dashboardso escalated when non-compliant or ineffective Ensure leadership accountability through structured governance, including SIF performance reviews, barrier assurance reporting, and board-level visibility of major hazard exposure and control performance.Engineering & Asset Integrity Provide governance and oversight of engineering systems that protect against major hazards, including:o Mechanical integrity programso Electrical integrity and arc-flash risk controlso Management of Change (MOC) governanceo 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 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 (temperature, pressure, gas concentrations) Smart sensors for molten metal transport systems and high-risk equipment Digital barrier management and critical control verification platforms Automated shutdowns and interlock systems to eliminate or minimize human exposureEnsure digital and automation initiatives are aligned with Serious Injury and Fatality (SIF) prevention principles and leading practices highlighted by the National Safety Council.Board Reporting & Risk Transparency Provide quarterly Board-level reporting on key process safety and major hazard indicators, including:o Tier 1 & Tier 2 Process Safety Eventso Critical Control Effectiveness Rateo Barrier Health Indexo High-Potential Incident (HiPo) trendso Mechanical Integrity backlog and risk exposureo Major Hazard Risk Heat Map Ensure the Board has clear, timely visibility of catastrophic risk exposure, emerging threats, and the effectiveness of mitigation and critical control performance. AUTHORITY/ DECISION MAKING: Authorized to stop or suspend high-risk operations (including molten metal transfer, high-voltage electrical work, gas system activities, confined space entry, or major lifting operations) when Critical Controls are not in place or verification evidence is not available. Holds decision rights to approve and enforce Critical Control Performance Standards, including verification frequencies, assurance methodologies, and minimum compliance thresholds. Has authority to require immediate corrective actions and set risk-based deadlines where major hazard exposure is elevated or controls are failing. Has decision-making accountability to approve or reject Management of Change (MOC) outcomes for modifications impacting major hazard risks, including process, equipment, technology, procedures, and operational condition Has the authority to challenge operational decisions and require revalidation of risk assessments where:o hazard studies are incomplete, outdated, or poorly scopedo critical controls are not clearly definedo residual risk is not within tolerable limitsQUALIFICATIONS & SKILLS:Required Qualifications: Engineering degree (Chemical, Mechanical, Electrical, or Process 15+ years in high-hazard industrial operations Deep expertise in:o HAZOP / LOPA / Bowtieo Critical Control Managemento Major Accident Preventiono Experience engaging regulators and Board committeeso Strong digital and data analytics literacyLeadership Expectations Demonstrate independent authority and confidence to escalate catastrophic risk concerns to Executive Management and the Board. Show courage and decisiveness to stop unsafe high-risk operations when critical controls are ineffective or degraded. Apply a strong systems-thinking mindset to identify underlying causes, systemic weaknesses, and cross-functional risk interactions. Influence senior leadership and operational teams to drive sustained process safety discipline, accountability, and performance improvement.Key KPIs (Board-Level) Zero Tier 1 catastrophic process safety events ≥95% Critical Control Verification effectiveness 100% Management of Change (MOC) compliance for major risk changes Reduction in SIF potential and high-potential events Closure of high-risk corrective actions within agreed target timeframes Why This Role is Critical in AluminiumAluminium smelting is a high-consequence industry involving: Molten metal above 700°C High-amperage electrical systems Combustible dust exposure Heavy lifting and crane operationsFailure of critical controls can result in multi-fatality events, major fires, and significant asset loss.This role ensures the organization shifts from reactive injury management to proactive catastrophic risk prevention through strong major hazard governance, critical control assurance, and Board-level visibility.