Maintenance and Reliability Manager at PepsiCo

Job Description

Accountabilities

• Ensure that short term and long term maintenance plans are developed and executed on the plant in a manner that will benchmark to PepsiCo best practice.

• Ensure maximum plant availability and reliability by leading and directing the maintenance team, ensuring at all times adherence to Safety legislation, relevant SANS codes and PepsiCo standards.

• Drive effective execution of routine, preventative and reliability maintenance schedules.

• Development of daily, weekly, monthly and 12 months maintenance plans and execution for Isando site while driving synergies with the other PepsiCo plants.

• Provide support on project scoping, execution and commissioning by ensuring key maintenance resources are part of each stage of the project.

• Management and development of the maintenance team and leverage skills in other SA sites to drive capability building.

• Effectively drive synergies with the Reliability and Utilities functions to optimise plant performance.

• Drive PEMM maturity and ensure adherence to maintenance standards with special focus on asset utilisation, planning preparation and maintenance execution.

• Undertake detailed analysis of the plant/assets to develop strategies and recommendations that will improve the reliability and performance of the plant, systems and maintenance effectiveness.

• Loss elimination - track the production losses and abnormally high maintenance cost assets, and then find ways to reduce those losses or high costs.

• Collaborate with Assets team members to develop, maintain and compile asset reliability, criticality and condition information necessary for the asset planning, delivery and maintenance strategies.

• Routinely produce root-cause analysis reports, respond to requests regarding reliability for the site.

• Professionally and systematically defines designs, develops, monitors and refines the Asset Maintenance Plan that includes: Value-added preventive maintenance tasks; Effective utilization of predictive and other non-destructive testing methodologies designed to identify and isolate inherent reliability problems.

• Provides input into the Risk Management Plan that will anticipate reliability-related, and non-reliability-related risks that could adversely impact plant operation.

• In full partnership with the operations team develops a plan to eliminate or reduce the losses through root cause analysis, obtains approval of the plan and facilitates the implementation.

• Manage the risk to the achievement of the organization’s strategic objectives in the areas of environmental, health and safety, asset capability, quality and production.

• Effectively use the following tools to identify and reduce risk: PHA - Preliminary hazards analysis; FMEA - Failure modes and effects analysis; CA - Criticality analysis; FTA - Fault tree analysis; ETA - Event tree analysis etc.

• Develops engineering solutions to repetitive failures and all other problems that adversely affect plant operations. These problems include capacity, quality, cost or regulatory compliance issues.

• Works with Project Engineering to ensure the reliability and maintainability of new and modified installations and ensure adherence to the Life Cycle Asset Management (LCAM) process throughout the entire life cycle of new assets.

• Participates in the development of design and installation specifications along with commissioning plans.

Qualifications/Requirements

Key skills / Experience required

• Bachelor’s Degree (Mechanical or Electrical).

• 5+ years’ experience in maintenance management role

• Strong knowledge of engineering concepts, including electrical, hydraulic and mechanical systems

• Ability to interpret blueprints, specifications and schematics

• Advanced computer skills, with emphasis on condition monitoring software/techniques

• Strong mechanical and electrical knowledge and aptitude

• Strong written and verbal communication skills

• Strong knowledge of preventive maintenance programs and the tools associated with failure detection (i.e. vibration analysis, oil monitoring, thermography) as well as the software associated with them.

• Minimum 7 years maintenance and reliability, production management, engineering or operations experience.

• Extensive and relevant reliability management experience.

• Continuous improvement tools.

• Experience with Computerised Maintenance Management Systems (CMMS) – ideally SAP

• Ability to interact effectively with blue collar workers as well as plant management

• Knowledge of Employee and Industrial Relations processes

• Ability to develop and manage good working relationships with internal departments (production, quality, logistics/RMS, accounting), contractors, suppliers inspectors and customers.

• Ability to interact effectively with people of different cultures.

• Strong verbal and written communication skills, including the writing of technical reports. the ability to interact effectively with people of different cultures.