Maintenance Manager

작업 내용

• The job holder must ensure that internal quality procedures are applied and adhered to within all areas of control.
• The individual must show that the change in culture is being driven throughout the areas of responsibility.
• Create an environment where people are open and constructive to new methods or strategies of work.
• Promote and reward success.
• Maximize reliability at the lowest economic cost , providing the required quality and ensuring a safe working environment

Creating systems, standards and competencies to

• Optimise maintenance resources
• Optimise asset life
• Minimise energy usage
• Minimise inventory
• Provide accurate records and data
• Responsible for Maintenance Programmes on site
• Responsible for the Maintenance Budget and organisation of the maintenance functions
• Ensure all direct reports have the required training and education to fulfil their roles
• Create and develop metrics to monitor and evaluate the cost and benefit of the department

TASKS AND RESPONSIBILITES:

Safety

• Deliver Health Safety objectives in line with company Must Win Battles and ensure that site procedures are strictly followed by the team and contractors in line with site/Company standards and safety improvement plans.

Planning:

• To set up and manage the Maintenance Department with a long term view of continuous improvement.
• To review internal performance and strategy in order to optimize the plant performance and efficiency.
• Predict the anticipated consumptions purchasing requirements.
• Ensure adherence to Effective Maintenance Planning , preventive (SEF s WP)
• Co-ordinate maintenance engineers efforts to make sure machinery / equipment is kept up to reliability and condition standards
• Identify areas for improvement and assign resources /time to address
• Contact and schedule contract resources and extra resourcing as needed
• To formulate and establish optimum spares holding levels
• To formulate and establish annual budgets for department.
• To formulate and develop capital expenditure plans for maintenance / replacement future investment needs.
• Define the needs, forward purchasing requirements and liaise with purchasing department.
• Monitor and record the variance of all maintenance budgets
• Oversee the installation, testing, operation, maintenance, and repair of facilities and production equipment.
• MWBs/Core Values

Staff

• Ensure the Maintenance Department is adequately resourced to allow the maintenance Day / Shift schedules to be maintained at all times.
• Define, implement and sustain an effective Maintenance Organisation
• Manage the Maintenance team
• To provide tight control and coordination of the development of all engineers
• To enhance the workforce training development and skill levels
• Ensure employees receive the appropriate training, with the appropriate modules, including 5S, TPM, 6 sigma, Kaizen, OEE.
• To establish and define training needs; to coordinate the training to ensure trainer and trainee understand and know the expectation/requirement of the training activity
• To measure the value and effectiveness of training provision
• To ensure the trainer has the required skills to train.
• To provide direct training to trainee as required.
• Taking into account the needs for shift cover define the roster and crewing levels to allow all operations to operate on time.
• Define and coordinate any overtime or as appropriate, the use of temporary/ agency workers
• Coordinate the placing of temporary workers, as necessary, with the employment agencies and HR dept
• Recruit employees; assign, direct, and evaluate their work; and oversee the development and maintenance of staff competence.

Lean 5S Initiatives

• Development of Lean systems and structures to aid and facilitate efficient maintenance process.
• Development of modern management techniques (Lean systems, value stream mapping, Kanban etc).
• Decide the necessary corrective actions and implement them to achieve all KPIs.
• Define and implement suggestions to improve the OEE of each line/function.
• All audits and controls for systems of work are executed at the desired frequency.
• Collaborate with the other departments: Operations, Purchasing, Sales, Engineering.
• Develop and implement reliability systems including preventive and condition monitoring activities to improve plant reliability.

Customer Quality

• Support the Customer focused vision of the Company. Maintain the fundamentals; Quality System, ISO 9001:2015 , Environmental standards, Health Safety standards.
• Actively participate in new product release process to ensure manufacturing is capable to achieve required specification and ensure ongoing Continuous Improvement / line efficiencies.
• Make sure quality assurance procedures are respected.
• Ensure non-conforming machinery / testing equipment are properly maintained.

Take part in process improvement, equipment development and investments:-

• Proposing technical solutions.
• Drive a quality culture through to all employees.
• Zero defect mentality to be enforced at all times.
• Be in a position that all employees appreciate who their customers are.
• Drive a complete Customer service culture throughout the areas of responsibility.
• .Customer is King.

Technical Norm Performance and Reporting

The manufacturing / engineering standards are respected

• Monitor the maintenance engineers performance with regard to MRP and technical norm performance for downtime and yield and other KPIs.
• Monitor for incorrect performance reporting. Take all required actions to correct and then prevent inaccurate reporting. Establish rules and procedures for this.
• Organise the maintenance schedule to optimise manning / equipment / cost
• Ensure adequate personnel cover for all aspects of maintenance operations.
• In case of process drift, define corrective actions.
• Analyse the daily report (24 hours) and maintain management reporting protocols and reports
• Produce the required management reports.
• Review / report on KPI performance and identify areas to improve. Act upon these improvements via the maintenance team and other resources.
• Take into account all the KPI Indicators which the department impacts (workflow, spare parts, workshop, lubrication, breakdown management, equipment reliability etc) develop strategies for improvement and implement.
• Process and analyse the data; report on developments and findings.
• Propose corrective actions as necessary during Morning Meeting.
• Take decisions within his field of remit, while keeping plant manager informed of the activities.
• Ensure budget constraints are respected.
• Make and implement improvement proposals.
• Develop the practice of Continuous Improvement throughout areas of responsibility.

Data and records

Development of continuous improvement processes (OEE)

• Develop and maintain accurate written procedures for the department and ensure these are followed.
• Report on the performance losses / Break Downs and implement corrective actions.
• All equipment has appropriate records, manuals, certification, PUWER assessments etc. These records are kept up-to-date and are current.
• Ensure all modifications to plant and process equipment are recorded, approved and compliant with all standards, follow MOC (Management of Change) Process, follow internal and external regulations.

Hygiene of Internal External Areas associated to your Responsibility Waste Control

The plant is a safe environment to work in

• The plant hygiene is maintained to high standards at all times.
• Change work ethic and culture towards a principle of self-starting and continuous improvement behaviour.
• Undertake regular plant tours.
• Ensure 5S cleanliness procedures in the work shop are adhered to.
• React to any drift; liaise with shop floor to maintain standards.
• Direct and facilitate the resources to ensure standards are maintained.
• Ensure equipment is fit for purpose.
• Propose new measures to take away drift in behavior.

Management activity:

• The company policies are distributed and explained to all personnel.
• Employees are competent and motivated.
• Any fall in standards is arrested and rectified immediately.
• Make improvement proposals.
• Give opinion on the performance of engineers.
• Propose sanctions.
• Motivate employees.
• Act as an interface role.
• Support Management.
• Participate within Plant Management - operations, quality meetings etc.
• Participate in the implementation of corrective actions.

OTHERS

• Develop and implement strategies that accelerate and improve current maintenance practices and processes to improve equipment performance, reliability and lower repair costs.
• Initiate, implement, and manage the plant maintenance programs based on best practices in our industry, with an emphasis on equipment condition inspections, planning/scheduling, high quality maintenance repairs, and safety, health environmental policies and procedures.
• Analyze operational data and equipment performance history to deliver improvements in critical maintenance related metrics including: unplanned downtime, PM compliance, schedule compliance, Mean-Time-Between-Failures, and maintenance related costs.
• Coordinate with cross-functional departments (Engineering, RD, Supply Chain, etc) to ensure operational effectiveness in life cycle cost considerations in equipment procurement activities.
• Develop and deliver comprehensive maintenance and reliability tactical training to maintenance resources.
• Leverage company subject matter experience/experts to advance current maintenance and reliability efforts through enhanced communication and best practice sharing by driving their application.
• Partner with worldwide operations group to coordinate maintenance activities in support of operational excellence.
• Regularly respond with advice to maintenance/equipment related questions, ensure access to up-to-date maintenance/operating procedures, and facilitate strong team communications activities.
• Establish, maintain, and leverage value from a computerized maintenance management system (CMMS) for tracking work orders, planned/predictive maintenance.
• Identify required equipment and process upgrades and effectively manage associated projects.
• Ensure accuracy in spare parts inventory and develop system as appropriate.

Qualifications Requirements

• Ideally, qualified to degree level - minimum Engineering
• Strong knowledge about process plant engineering, Lean Management and Six Sigma Approach desired.
• IT skills (MS office, ERP systems, CMMS, CAD, SAP etc.).
• Strong knowledge of engineering concepts, including electrical, hydraulic and mechanical systems
• Experience in Automation
• Business/management background to be able to deliver budget reports and cost assumptions.