Maintenance Manager

Overview
The Maintenance Manager's role is to ensure the efficient and reliable operation of all physical assets and equipment, including both surface and underground operations. This involves minimizing downtime and implementing effective maintenance practices to ensure continuous operations. Key responsibilities include planning, coordinating, and executing preventive, corrective, and predictive maintenance programs while overseeing a team of skilled technicians or contractors as well as multiple workshop operations. Additionally, the Maintenance Manager must ensure that all maintenance activities are conducted safely, adhere to budget constraints, and comply with regulatory requirements and organizational standards.
Qualifications

A Bachelor's degree in Mechanical or Electrical Engineering
Mechanical / Millrite red seal

Advantageous Requirements:

Experience in Explosives manufacturing will be an added advantage

Experience

5 years demonstrated experience in a Maintenance management role
5 years demonstrated understanding of the principles and applications associated with manufacturing operations, maintenance and quality
Demonstrated experience on trucks and heavy machinery.

Duties
Maintenance Strategy Development and Execution

Develop and implement maintenance plans that ensure equipment reliability and minimize unplanned downtime.
Ensure the maintenance strategy aligns with the overall operational and business goals.
Develop effective workshop operational schedule to ensure delivery of effective maintenance and increased availability of assets
Continuously review and improve maintenance procedures to reflect technological advancements and operational needs.
Create and track key performance indicators (KPIs) like Mean Time Between Failures (MTBF) and Mean Time to Repair (MTTR) to assess the effectiveness of the maintenance strategy.

Equipment and Asset Reliability

Ensure all equipment is regularly inspected, serviced, and repaired to maximize uptime and reduce the risk of breakdowns.
Implement predictive maintenance techniques by leveraging data analysis, condition monitoring, and diagnostics.
Ensure proper calibration, lubrication, and adjustment of all machinery to maintain optimal performance.
Reduce failure rates by addressing root causes of malfunctions, optimizing repair times, and minimizing stoppages.

Cost Management and Budget Control

Develop, monitor, and manage the annual maintenance budget, including labour, spare parts, equipment, and contract costs.
Implement cost-saving measures such as bulk purchasing, vendor negotiations, and optimizing resource usage (parts, materials, and energy).
Control overtime and unnecessary expenses by optimizing shift coverage, scheduling, and resource allocation.
Verify financial reports on maintenance costs, justifying expenditures and identifying opportunities for cost improvements.

Compliance with Safety, Health, Environmental, and Quality Standards

Ensure that all maintenance activities follow health, safety, environmental, and quality standards to reduce risks and avoid legal issues.
Conduct regular safety audits and risk assessments, addressing any potential hazards.
Implement and enforce safety procedures and protocols to prevent workplace accidents and ensure a safe working environment.
Ensure compliance with Process Safety Management (PSM) to minimize process-related incidents in equipment handling.
Maintain an up-to-date safety record, documenting all incidents and corrective actions taken.
ISO requirements and BME standards compliance

Plant and Equipment Optimization

Implement lean maintenance techniques and methodologies, such as Total Productive Maintenance (TPM), to reduce waste and improve equipment reliability and efficiency.
Analyze equipment performance data and trends to optimize asset usage, enhance operational processes, and extend equipment lifespan.
Introduce automation, predictive analytics, and condition-based monitoring technologies to ensure more accurate and timely interventions.
Propose and implement equipment upgrades and modernization initiatives when necessary to improve overall plant efficiency.

Maintenance Scheduling and Execution

Develop detailed maintenance schedules, ensuring preventive maintenance occurs at optimal intervals to minimize equipment failures and unscheduled downtime.
Coordinate closely with operations teams to schedule maintenance during non-peak hours or planned outages to avoid operational disruptions.
Ensure timely response to equipment failures and prioritize urgent repairs to restore normal operations as quickly as possible.
Manage and oversee maintenance activities performed by in-house teams and external contractors to ensure work is completed on time and within scope.

Team Leadership and Development

Lead, train, and mentor the maintenance team, ensuring they possess the required technical skills and certifications.
Conduct performance reviews, set individual and team goals, and provide continuous feedback to ensure alignment with business objectives.
Ensure the maintenance team adheres to safety and operational standards, providing ongoing training as necessary.
Promote a culture of continuous improvement within the team, encouraging innovative ideas and problem-solving approaches.

Job Competencies
Vendor and Contractor Management

Establish relationships with key vendors and contractors, ensuring that external services meet quality, safety, and cost standards.
Negotiate service agreements and contracts, ensuring the company receives the best value for outsourced maintenance work.
Manage the performance of contractors during specialized maintenance projects, ensuring timely completion and compliance with safety and quality standards.
Continuously assess vendor and contractor performance, adjusting partnerships to improve outcomes.

Continuous Improvement and Innovation

Continuously evaluate maintenance procedures and practices to identify areas for improvement and increase operational efficiency.
Explore and implement new technologies and methodologies that enhance maintenance effectiveness and productivity.
Foster a culture of innovation by encouraging team members to propose new ideas and solutions to optimize maintenance activities.
Participate in industry benchmarking and incorporate best practices from leading organizations to improve internal processes.

Maintenance Reporting and Documentation

Maintain detailed records of maintenance activities, including inspections, repairs, parts replacements, and equipment performance data.
Prepare regular reports for senior management on maintenance KPIs, budget performance, and equipment reliability.
Ensure that all maintenance documentation complies with legal, safety, and quality standards and is readily available for audits or regulatory inspections.
Use maintenance management software to track and analyze data, identifying trends and opportunities for improvement.
Assist in the development process of the maintenance management system in D365

Job Related Skills

Proven computer literacy – MS Office
Knowledge of Microsoft D365
Attention to detail
Ability to keep track of and report on activity
Ability to reference and interpret technical operating manuals, specifications drawings and diagrams
Knowledge of Six Sigma, total quality management
Preventive and Predictive Maintenance
Technical Problem-Solving and Troubleshooting
Equipment Knowledge
Computerized Maintenance Management Systems
Lean Manufacturing/Total Productive Maintenance (TPM)
Process Safety Management (PSM)
Team Leadership and Supervision
Project Management and Task Delegation
Training and Development of Staff
Resource Allocation and Optimization
SHERQ Compliance
Knowledge of Industry-Specific Safety Standards (ISO, OSHA)
Risk Management and Hazard Analysis
Root Cause Analysis (RCA)
Data-Driven Decision Making
Continuous Improvement and Process Optimization
Budgeting and Cost Control
Resource Optimization and Spare Parts Management
Supplier and Vendor Negotiation
Cross-Functional Collaboration
Vendor and Contractor Management
Reporting and Documentation

General

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