Job Summary: Coordinates the maintenance of machines for machining line, by directing, organizing and guiding the maintenance work and mechanical, electrical, electromechanical, hydraulic/pneumatic repairs performed on these machines, as well as the assembly and installation of new machines. Their primary responsibility is to oversee maintenance operations to minimize downtime, maximize efficiency, and ensure a safe working environment. Key Responsibilities: 1. Strategic Planning and Scheduling Developing Maintenance Plans: The Maintenance Manager creates long-term maintenance plans to ensure the smooth operation of all equipment and machinery. This involves creating schedules for preventive, corrective, and predictive maintenance. Prioritizing Maintenance Tasks: Assessing which equipment or machinery requires immediate attention based on operational priorities, safety, and production requirements. Scheduling Maintenance Activities: Coordinating maintenance activities to minimize disruptions to the production process, ensuring maintenance tasks are performed during non-peak hours or downtime when possible, with support of company software and policy (e.g. SAP, EMS) 2. Team Management and Leadership Managing Maintenance Staff: Supervising a team of maintenance technicians, engineers, and support staff. The Maintenance Manager ensures that the team is properly trained and equipped to handle their tasks. Maintaining the hormonal coordination between various depts like Production, Quality, Process Engineering, Safety, HR and SCM Assigning Tasks: Delegating daily maintenance tasks to the team based on skills, experience, and the complexity of the work. Training and Development: Providing ongoing training and development to staff to ensure they are updated with the latest maintenance technologies and safety practices. Training may include specific equipment handling, troubleshooting, and safety protocols. Promotes the technical development of the staff and of the training needs. Motivating the Team: Encouraging a culture of teamwork and high performance by providing clear guidance, feedback, and recognition. 3. Preventive and Predictive Maintenance Establishing Preventive Maintenance Programs: Implementing and overseeing regular maintenance schedules to proactively prevent equipment failures before they occur. This could include checking machine parts, lubrication, alignment, and calibration as per PM check sheet. Monitoring Predictive Maintenance: Using data and technology (e.g., condition monitoring) to predict when maintenance is required based on equipment condition or PM records. Tracking Equipment Performance: Monitoring key performance indicators (KPIs) such as Safety, MTTR, MTBF, Energy, equipment uptime and maintenance costs to assess the effectiveness of maintenance activities. Prepares reports on maintenance aspects, defines preventive and predictive maintenance actions. Outlines technical guidelines and procedures for equipment maintenance 4. Troubleshooting and Problem-Solving Diagnosing Equipment Failures: When equipment malfunctions, the Maintenance Manager is responsible for quickly diagnosing the root cause of the issue to minimize downtime. Implementing Solutions: Once the problem is identified, the Maintenance Manager either personally addresses it or coordinates with maintenance staff to resolve the issue as quickly as possible. Root Cause Analysis (RCA): Conducting detailed investigations into recurring equipment failures to determine the underlying causes and develop strategies to prevent future/repetitive breakdowns. 5. Budgeting and Cost Control Creating and Managing Maintenance Budgets: The Maintenance Manager prepares and manages the maintenance departments budget, which includes costs for service, equipment, tools, and spare materials. Cost Optimization: Identifying ways to optimize maintenance costs without compromising the quality or safety of operations. This could involve sourcing more cost-effective parts, negotiating with suppliers, or implementing energy-saving initiatives with help of procurement team. Tracking Maintenance Expenses: Monitoring and controlling spending on repairs, replacements, and spare parts to ensure that the maintenance budget is adhered to. 6. Equipment and Facility Management Overseeing Equipment Maintenance: The Maintenance Manager ensures that all machinery, equipment, and tools are properly maintained to prevent production delays. This involves not only fixing equipment but also tracking its lifecycle, deciding when replacement or upgrades are necessary. Facility Maintenance: Ensuring that the facility itself is maintained, including 132 KVA substation, ETP, STP, lighting, plumbing, and other infrastructure, to provide a safe and comfortable working environment. Managing Spare Parts Inventory: Overseeing the spare parts inventory to ensure that necessary parts are available for repairs and replacements without overstocking. 7. Safety and Compliance Ensuring Safety Standards: Ensuring that all maintenance activities comply with defined safety regulations, as well as internal company safety standards. This includes following procedures for working with hazardous materials or heavy machinery. Conducting Safety Audits: Regularly auditing maintenance operations to ensure that safety protocols are followed, and risks are minimized. Training Staff on Safety Protocols: Providing ongoing safety training for the maintenance team, including safe machinery handling, personal protective equipment (PPE), and emergency response procedures. Maintaining Compliance Records: Keeping accurate records of inspections, safety/electricity audits, equipment maintenance logs, and certifications to ensure local and regulatory compliance with global and industrial guidelines. 8. Project/ Service Management Managing External Contractors: When specialized maintenance tasks or repairs are required, the Maintenance Manager may need to work with external contractors or vendors. Sourcing Spare Parts and Materials: The manager coordinates the procurement team for necessary materials and parts from vendors, ensuring they meet quality standards and are delivered on time. Evaluating Vendor Performance: Periodically evaluating vendor performance to ensure that they meet contractual agreements in terms of quality and delivery timelines. 9. Data Analysis and Reporting Reporting to Senior Management: Providing regular reports to senior management on maintenance performance, key issues, and the status of ongoing projects. This includes providing insights into areas that need improvement. Using Data for Decision-Making: Analyzing historical data to identify trends, optimize maintenance schedules, and plan future improvements in equipment and processes. 10. Continuous Improvement and Innovation Identifying Opportunities for Improvement: Continuously evaluating maintenance practices and equipment performance to identify opportunities for improvement. This could involve adopting new technologies, improving workflows, or updating preventive maintenance programs. Implementing New Technologies: Keeping up to date with advancements in maintenance technologies, such as predictive maintenance tools, automation, and remote monitoring systems, and incorporating them into the maintenance strategy. Fostering a Culture of Improvement: Encouraging the maintenance team to suggest improvements to processes, procedures, and systems. Actively seeking employee input to increase efficiency and effectiveness.
