A. Maintenance & Reliability Management
- Develop, implement, and manage a comprehensive preventive and predictive maintenance (PPM) program across all plant equipment.
- Ensure maximum equipment availability, reliability, and Overall Equipment Effectiveness (OEE).
- Establish and closely monitor core engineering KPIs, particularly Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR).
- Oversee the end-to-end maintenance of kilns, presses, glazing and application lines, dryers, conveyors, sorting and packing equipment, utilities, and material-handling systems.
- Establish strict maintenance plans, schedules, standards, and records to significantly reduce breakdowns and unplanned downtime.
- Analyse complex equipment failures and lead rigorous root-cause investigations and corrective actions.
- Monitor equipment condition, critical spares inventory, and overall maintenance performance indicators.
B. Engineering & Plant Improvements
- Identify and implement strategic projects to improve equipment reliability, overall production capacity, energy efficiency, process stability, and product quality.
- Provide advanced engineering support for process changes, new product introductions, equipment upgrades, and production trials.
- Prepare comprehensive technical scopes, cost estimates, and business cases for capital and improvement projects.
- Manage engineering projects flawlessly from initial planning and procurement through to installation, commissioning, and final handover.
- Ensure all engineering changes are meticulously documented and that relevant operating and maintenance procedures are continuously updated.
C. Engineering Projects & Capital Works
- Plan, budget, and execute high-value capital expenditure (Capex) projects, including equipment upgrades, facility automation, capacity expansion, and energy-saving initiatives.
- Manage project timelines, external contractors, vendors, and strict budgetary controls.
- Lead the installation, commissioning, and qualification of new manufacturing machinery.
- Drive forward-thinking automation and digitalization initiatives across the plant (e.g., SCADA systems, IoT monitoring, and CMMS integration).
D. Utilities and Infrastructure
- Ensure the highly reliable operation and maintenance of all plant utilities and services, including electrical systems, compressed air, water, gas, and other critical site systems.
- Monitor utility consumption trends and identify innovative opportunities to reduce energy and resource usage without compromising safety, quality, or production output.
- Coordinate all statutory inspections, mandatory servicing, and compliance records for relevant equipment and installations.
E. Continuous Improvement & Cost Optimization
- Lead continuous improvement initiatives by championing Lean, TPM, Six Sigma, or Kaizen methodologies.
- Identify and rapidly implement cost-reduction opportunities across maintenance, energy consumption, and spare parts procurement.
- Optimize the spare parts inventory framework to balance financial cost against operational availability.
- Continuously benchmark plant performance metrics against industry best practices.
F. Safety, Compliance & Regulatory
- Ensure that all engineering and maintenance activities strictly comply with DOSH, DOE, BOMBA, and other local statutory requirements.
- Enforce absolute adherence to workplace safety standards, lock-out/tag-out (LOTO) protocols, and permit-to-work (PTW) systems.
- Conduct thorough risk assessments and lead formal incident investigations when required.
- Ensure all pressure vessels and other regulated industrial equipment are inspected and certified as legally required.
G. Team Leadership & Development
- Lead, coach, and develop a multi-disciplinary maintenance and engineering team comprised of mechanical, electrical, instrumentation, and automation technicians/engineers.
- Strategically plan manpower requirements, shift rosters, and ongoing skills training programs.
- Build and sustain a high-performance culture rooted in accountability, safety, and technical excellence.
- Manage performance reviews, disciplinary actions, and departmental succession planning.
H. Cross-Functional Collaboration & Reporting
- Work collaboratively with Production, Quality, Safety, Procurement, and other departments to ensure maintenance priorities align with overarching operating plans.
- Report engineering performance, operational risks, major breakdowns, project progress, and resource requirements directly to executive leadership (General Manager / Group MD).
- Maintain highly accurate documentation for equipment, maintenance logs, project milestones, and compliance.
I. Vendor & Stakeholder Management
- Manage and cultivate strategic relationships with equipment suppliers, OEMs, external contractors, and service providers.
- Negotiate favorable service contracts and spare parts pricing.
- Collaborate closely with Production, QC, and Finance teams on large-scale cross-functional initiatives.
3. Key Performance Indicators (KPIs)
- Equipment: OEE optimization; minimization of unplanned downtime (hours/month).
- Maintenance: PPM completion rate; MTBF; MTTR.
- Cost: Maintenance cost per m2; energy cost per m2; documented utility and energy efficiency improvements.
- Projects: Delivery of Capex projects strictly on-time and on-budget.
- Safety: Zero LTI (Lost Time Injuries); maintaining exemplary safety audit scores.
- People: Execution of targeted training hours; advancement of the technician competency matrix.
