Mechanical Engineer P O
Resume:
PERSONAL INFORMATION
JOSEPH MUSONDA
Plot No. ***18/73 Kitwe West, Kitwe, Zambia
+260-***-****** +260-***-****** **************@*****.***
Male 01/09/1987 Zambian Married C1 Driving License
PROFESSIONAL SUMMARY
Professional Mechanical Engineer with over 12 years’ experience in copper/zinc processing plants and a proven expat record. I lead
teams across multinational sites to deliver safe throughput and high plant availability, shutdown governance and reliability (RCM, RCA,
FMEA), with strong OPEX/CAPEX control and statutory compliance. Data-driven (SAP, Navision, PI) and hands-on experience known
for restoring production fast and turning field insights into durable upgrades.
WORK EXPERIENCE
6th Sept 2024 ToDate
Position: Process Plant Field Mechanical Engineer-Expat
Company: Bisha Mine Share Company, 61 Mariam Gimby Street Asmara, P.O. Box 4276 State of
Eritrea
Executing field inspections of critical assets (SAG mills, crushers, conveyors) to
identify wear/corrosion – prescribing on-the-spot repairs or modifications to prevent
failures.
Leading urgent field repairs during breakdowns (e.g., slurry pump seizures, conveyor belt tears) –
directing crews to restore production.
Designing and installing plant modifications (pump upgrades, pipeline resizing) from concept to
commissioning – developing fabrication drawings in AutoCAD/SolidWorks and overseeing field
installations.
Managing asset integrity projects for structural components (conveyor supports, thickener
walkways) – conducting UT thickness testing and specifying repair methods like plate
reinforcement or grouting.
Performing root cause failure analysis at the failure site – inspecting fractured components and
modifying designs to extend life.
Securing statutory compliance through field audits of pressure vessels and cranes – coordinating
inspectors during shutdowns.
Developing CAPEX justifications for process plant upgrades/improvements – presenting fieldcollected failure data to secure AFE approvals.
Documenting as-built conditions post-modification – sketching field changes to drawings at the
installation site and updating CMMS records.6th Sept 2022 To 6th
Sept 2024
Position: Process Plant Maintenance Reliability Supervisor- Expat
Company: Bisha Mine Share Company, 61 Mariam Gimby Street Asmara, P.O. Box 4276 State of
Eritrea
Responsible for the overall safety and effectiveness of the Mechanical, Electrical and
Instrumentation maintenance reliability functions for all fixed plant assets.
Leading Reliability Centered Maintenance Processes which include RCA’s, FMEA Review,
Critical Spare Parts identification and review, and improvement analysis.
Minimization of downtime and failure rates to maximize engineering availability of all assets and
assist operations and maintenance teams in establishing critical spares and tool inventories.
Recommending measures to improve production methods, equipment performance and
implementation of appropriate scheduled preventative and predictive maintenance strategies.
Analyzing and developing methods to determine maintenance demands and reliability
of components, equipment, and processes.
Acquiring and analyzing equipment and downtime data.
Preparing diagrams, charts, drawings, calculations, and reports to define downtime and reliability
problems.
Determining cost advantages of different maintenance strategies and developing action plans for
cost effective reliable process equipment to avoid equipment outages.
Designing and developing new and unique repair methods and procedures.
Initiating, developing, and executing a "Preventative Maintenance Optimization" project to keep
the maintenance system up to date.
Ensuring adequate documentation of historical work orders, equipment downtimes are kept and
updated in the computerized maintenance management system (NAVISION) for future analysis.
26th Nov 2021 to 6th
Sep 2022
Position: Coordinator- Planning, Engineering and Reliability
Company: Barrick Lumwana Mining Company, Kalumbila, Zambia
Ensuring a safe and clean work environment by enforcing company safety policies and
procedures.
Liaising with Process operations to specify weekly downtime requirements and defining
interactions required between the different operation groups.
Driving the planning and scheduling processes of all major maintenance shutdowns throughout
the year and assisting the Maintenance Manager in the development of yearly department
budget.
Leading Reliability Centered Maintenance Processes which include RCA’s, FMEA Review,
Critical Spare Parts identification and review, and improvement analysis.
Assisting with the selection and supervision of contractors.
Leading PMO programs that ensure preventive maintenance and inspection programs are
relevant and technically adequate.
Ensuring adequate documentation of historical work orders, equipment downtimes are kept and
updated in the computerized maintenance management system (SAP) for future analysis.
Supporting the planning and scheduling process by helping to organize Mechanical, Electrical,
Instrumentation and Process Departments requirements.
Leading the coordination and tracking of the yearly maintenance shutdown tasks to ensure timely
and efficient completion of work within the defined critical path.
Assisting in implementing action plans and other problems associated with safety and reliability
to avoid recurrences.
Communicating the maintenance KPI’s on a weekly and monthly basis, analyzing them and
suggesting ways to improve performance.
Ensuring work management systems are followed.
Ensuring Management of Change processes are followed for every improvement project.10th Jan 2021 to 26th
Nov 2021
Position: Reliability Engineer
Company: Barrick Lumwana Mining Company, Kalumbila, Zambia
Development and implementation of maintenance work performance monitoring measures and
key performance indicators (KPIs).
Assisting in the planning and implementation of Reliability Centered Maintenance (RCM)
by assessing asset and sub-asset criticality rankings, performing failure analysis, and
recommending mitigation strategies.
Conducting regular and formal downtime analysis for critical process plant equipment –
including but not limited to, Gyratory crushers, conveyors, SAG/Ball mills, thickeners, Press
filters, blowers, compressors, and pumps.
Identifying, quantifying, and implementing initiatives to improve overall equipment reliability, safe
operation, and performance.
Coordinating plant equipment improvement trials, including technical input, tracking, reporting,
and ensuring alignment of all trial work with Management of Change policy.
Assisting with development of annual reliability C integrity maintenance budget as well as
managing costs within budget.
Liaising with suppliers and contractors to organize emergency or planned repairs of
assets/equipment inhouse/in-situ or externally.
Assisting in management of shutdown activity project work specifically related to critical plant
equipment.
Providing supervision of contractors for activities directly related to reliability improvement
projects whilst ensuring work quality meets safety, health, and environmental compliance with
Barrick and applicable regulatory authorities.
Carrying out cold/hot commissioning and starting up activities of new assets and equipment.
Facilitating and leading root cause failure analysis – as required using systematic RCA
techniques.
Identifying and supporting the implementation of corrective actions that mitigate risk to an
acceptable level, ensuring all analyses and activities are appropriately documented.
1st Nov 2017 to 10th
Jan 2021
Position: Project Mechanical Engineer-Nkana Concentrator
Company: Mopani Copper Mines Plc, P.O Box 22000, Kitwe, Zambia
Preparation of Capital expenditure budgets for all Nkana concentrator projects which are in line
with Mopani’s 5-year Capital plan.
Preparation of Application for Expenditure (AFE) documents and ensuring timely approvals.
Preparation of scope of works, BOQ’s and technical specifications documents in readiness for
tendering.
Planning, coordinating, and monitoring assigned projects.
Supervision of all mechanical equipment (i.e., crushers, Mills, Conveyances, thickeners,
gearboxes, agitators etc.) refurbishments, installations, and commissioning.
Analyzing project specifications, developing work schedules, and delegating tasks to different
teams.
Ensuring that each project stays within the allocated budget and timeframe.
Scheduling meetings and training sessions when necessary.
Constantly monitoring compliance to applicable codes, practices, QA/QC policies.
Following up commitment dates, preparing project status reports and ensuring project is on due
course.
Liaison with supply department and vendors to ensure timely delivery of project spares. Liaising with Mine safety department for statutory testing of overhead cranes, mobile cranes, tele
handlers, pressure vessels etc.
Interpreting technical (structural construction/mechanical equipment installation) drawings as well
as offering technical solutions/ clarifications to engineering design situations as they arise.
Ensuring project close out and handover documentation completed on time.
Ensuring a safe and clean work environment by enforcing company safety policies and
procedures.
6th May 2016 to 27th
Dec 2016
Position: Section Mechanical Engineer -Nkana Concentrator (Grinding and Flotation section)
Company: Mopani Copper Mines Plc, P.O Box 22000, Kitwe, Zambia
Maintenance of plant mechanical equipment/machinery in area of responsibility to ensure above
90% equipment availability.
Ensuring 100% preventive maintenance compliance.
Preparing weekly equipment performance reports.
Leading continuous plant improvements/modifications in the assigned section
Ensuring statutory compliance of all equipment/ machinery (i.e., pressure vessels, lifting
appliances and cranes.) in accordance with mining regulations.
Monthly plant shutdown resource planning, monitoring, and review.
Striving to maintain equipment within section’s allocated budget.
Coordinating and supervising mini projects in area of responsibility.
Conducting plant inspections to highlight all non-conformities and ensuring corrective actions
are taken.
Enforcing safety standards in accordance with companies HSE policy.
7th April 2014 to 6th
May 2016
Position: Senior Assistant Mechanical Engineer-(Engineer in training program)
Company: Mopani Copper Mines Plc, P.O Box 22000, Kitwe, Zambia
Nkana Concentrator- Crushing, Conveyors, Grinding and Flotation Sections
Mindola Mine Site Mobile section.
Mindola Mine Site (Hoist Section).
Mopani Copper Mine, Mindola Mine Site (Services Section)
Mopani Copper Mine, Central shaft (Services Section)
25thDec 2013 to
30th March 2014
Position: Condition Monitoring Engineer
Company: SKF-Zambia Limited, 20 Langashe Street, Kitwe, Zambia
Education and Trainings
2008 to 2013 Bachelor of Engineering
University of Zambia, Great East Campus Lusaka Zambia.
2004 to 2006 Grade Twelve (12) School Certificate
Hillcrest National Technical High School, Livingstone (Zambia)
PERSONAL
SKILLS
Effective communication and networking skills gained from experience as Section Mechanical
Engineer. Projects i.e., liaising between internal department as well as suppliers/vendors. Good supervisory skills, project management and people management skills gained as a Section
Mechanical Engineer- Projects responsible for project planning, organizing, coordination and
tracking tasks among subcontractors through daily interfacing meetings.
Rotating machinery vibration analysis, dynamic balancing, and shaft laser alignment.
Sound knowledge and hands-on experience on maintenance of pumps, crushers, conveyors,
gearboxes, ball/SAG mills, blowers, compressors, hydraulic systems and bearing maintenance.
Excellent drawings interpretation skills, understanding of hydraulics as well as pneumatic gained
through experience working as a Section Mechanical Engineer. -Projects responsible for
overseeing mechanical equipment installations.
Knowledge of ISO55000 physical asset management gained as Reliability Engineer.
Command of NAVISION, SAP, Pronto-XI, Asset Management Tool-AMT, Syspro and orb
fusion.
Good Knowledge of PI-Process Book and Siemens PCS7.
Good command of AutoCAD, inventor fusion, SolidWorks.
Excellent Microsoft Project, Excel, Word, and Power Point. Skills obtained from creating
daily weekly reports and presentations.
Excellent command of SKF@apitude software for vibration analysis/condition monitoring,
experienced gained as a condition monitoring engineer.
HONORS AND
AWARDS
Award winners for Mopani Copper Mines 100days Rapid results Projects
New concentrator HAZOP study (Hazard and Operability) sessions
Memberships Engineering Institution of Zambia
The Engineering Registration Board- Professional Engineer
Projects 1. 2017 to 2018 Nkana concentrator Grinding Mills overhauls- USD 7.45 Million.
2. 2017 to 2018 Nkana Concentrator Process optimization s regrind circuit- USD 4.23Million
3. 2018 to 2019 Nkana concentrator Flotation cells rehabilitation – USD 1.3 Million.
4. 2018 to 2019 Nkana concentrator – Replacement of 18’’ tailings pipes- USD 1.94 Million.
5. 2018 to 2019 Nkana concentrator- Crusher Refurbishments- USD 1.7 Million.
6. 2019 to 2020 Nkana concentrator- Refurbishment of steel structures- USD 499K.
7. 2022 – Barrick Lumwana - Stockpile Feed conveyor structural stabilization- USD 3 Million
8. 2022- Barrick Lumwana- Cyclone feed pump upgrade project- USD 4.5 Million
G. 2022- Barrick Lumwana- Final tails pump system upgrade project- USD 450K
10. 2022- Bisha Mine share company- Tails thickener refurbishment. - USD 2.7 Million
11. 2022- Bisha Mine share company- Copper con thickener refurbishment. - USD 2.5 Million.
References 12. Mr. Andrew Brown, Manager Maintenance - Planning, Engineering, Reliability, Capital projects,
Barrick Gold- Lumwana Mining Company, Cell +61-409******, Email:
**************@********.***.**
13. Mr. Evans Tembo, Planning, Engineering and Reliability Superintendent, Lumwana Mining Company, Cell:
14. Mr. Christopher Bruce, Project Manager- Nkana Concentrator, Mopani Copper Mines P.O. Box 22000
Kitwe, Cell: +260-***-******.
15. Mr. Chimuka Michelo, Engineering Superintendent-Projects, Nkana Concentrator, Mopani Copper Mines
P.O. Box 22000 Kitwe, Cell: +260-***-******.
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