Maintenance Manager at AVI Limited

Job Description
This job profile is for a qualified and experienced Maintenance Manager Packing / Utilities & Services at National Brands Limited Rosslyn Snacks.  The successful incumbent will be a report to the Engineering Manager and have primary responsibilities of:

• Be appointed as the GMR 2.7 for the site and ensure all statutory compliance takes place according to the OHS Act and its regulations. Ensure that all legal inspections and risk assessments are carried out and that general safety is adhered to in area of responsibility.
• Implementing and execute engineering standards, maintenance strategies and asset plans for property, plant and equipment in the Processing and Packaging section, using SCADA and CMMS software.
• Be an expert in preventative maintenance and compliance to statutory requirements of snack processing equipment, utilities and boilers, air compressors, packaging equipment, gas burners, infrastructure and buildings.
• Provide supervision for the execution of equipment maintenance through the effective utilisation of key in-house resources, original equipment manufacturers and contracted services in the organisation.
• Plan and manage maintenance shutdowns and improve plant reliability and equipment availability using OEM, RCM, 5Why and RCA processes.
• Improve spare parts quality, consumption and availability of work done on spares and rotables.
• Deliver on the energy strategy and key performance indicators of energy consumption and savings for the section.
• Plan, prepare and execute on allocated maintenance budget and projects in accordance with the priorities and the necessities of the business, with due regard for cost control.
• Lead a team of maintenance foreman, engineer, technicians, millwrights, artisans and handymen.
• Subscribe to the values of NBL and foster a culture of care, ownership, accountability and teamwork with the other departments in the site and the wider engineering fraternity at other NBL factories.

The abovementioned activities shall be conducted in compliance with the Occupational Health and Safety Act, No. 85 of 1993 and all relevant NBL policies and procedures.

This profile acts as a guide and any additional work outcomes in-line with the role may be required to be performed by the incumbent.

 Job Specification - Key Performance Areas (main outputs and responsibilities for this position):

Health, Safety and Environment

• Be the GMR2.7 legal appointee and the custodian for the organisation on all statutory inspections of plant and equipment in area of responsibility.
• Adhere to and ensure compliance by subordinates to the company safety policies and procedures by keeping the employees accountable for their actions, as well as for the lack thereof.
• Assist with implementation, obtainment and maintenance of relevant health, safety and environmental management system standards, SANAS, ISO and good engineering procedures.
• Ensure equipment compliance with relevant safety regulations and keep records of all statutory inspections and compliance documents for inspection and audit purposes.
• Ensure facilities and infrastructure are conducive to employee health and wellness
• Ensure that integrity of site emergency and warning systems are maintained (alarm systems, emergency equipment).
• Drive a safety culture in the department & section – Housekeeping, PTW, LOTO, SOP’s.

Food Safety

• Adhere to, and ensure compliance by subordinates to FSSC 22000, AIB and ISO principles
• Actively participate as an integral member of the established site HACCP team
• Ensure site infrastructure and equipment are installed and maintained in such a manner that Food Safety is not compromised.
• Ensure standard of utilities (water and compressed air) is in line with Food Safety Standards in your area
• Manage all requirements related to CCP and OPRP equipment (calibration, validation, maintenance, etc.)
• Raising, and closing out of NCR’s in connection with equipment related food safety incidents.

Plant availability, reliability and uptime

• Execute relevant maintenance activities and ensure effective utilization of the preventative maintenance and material management systems.
• Develop maintenance plans and procedures for critical equipment to achieve preventative and proactive maintenance.
• Coach and assist with critical problem solving and utilization of key asset care techniques of OEM, RCM, 5Why and RCA processes for breakdowns.
• Ensure the breakdown processes are adequate to achieve a zero-repeat incident goal.
• Review OEM recommended spares and identification and classification of critical spares
• Management of equipment warranties, ensuring new equipment information is captured on the warranty register and warranties are upheld

Engineering and maintenance strategy execution

• Assess the current maturity of the department and strategically plan what the future goals are which must align to the engineering departments objectives
• Identify opportunities for continuous improvement
• Participate in scoping and procurement of new plant equipment to ensure adherence to site Engineering standards
• Assist in the development of the annual maintenance plan
• Optimize plant spares to ensure that the correct number of spares are being kept (stockholding) and rotables are managed appropriately.
• Manage job card effectiveness including monitoring, allocation, close-out and backlog

Budget and cost

• Compilation of annual maintenance budget for the section
• Daily maintenance cost control, escalation and reporting
• Manage the sections costs in line with budgets
• Implement cost reduction and productivity initiatives
• Assist with compiling annual capex budgets
• Execute and monitor service level agreements and contractor management services
• Investigate equipment failures to stop re-occurrences, cost of repair and conduct call out and overtime analysis.
• Monitor preventative to corrective maintenance cost ratio for the area

Projects

• Assist central and site project team with installation of new plant and equipment to facilitate commissioning and handover.
• Establish relationships between various functions for critical input into maintenance projects and action lists.

Leading and management

• Manage resource allocation and time in accordance with Basic Conditions of Employment and Labour Relations Act, ensuring appropriate resources for departmental requirements.
• Ensure employees in the team understand and practice the NBL values.
• Lead by influence and stimulate a culture of high performance, accountability and leadership with clear goals and aligned efforts.
• Ensure team members have the means to do their jobs, the ability to execute on tasks and are held accountability through recognition and discipline for their outputs.
• Updating and implementation of skills matrix as well as coordination of training
• Plan the leave, training, and development for the sub-ordinates in line with the engineering strategies developed for the department.
• Management of relationships and accountability with original equipment manufacturers, contractors and suppliers.
• Lead critical contractors and form good working relationship with key service providers

Minimum Requirements:

 Qualifications:

• Completed qualification (NDip / BTech / BEng) in Mechanical or Electrical Engineering

 Certification:

• Eligibility to write Factory GCC will be an advantage

 Experience:                                                                   

• 5 years in a manufacturing plant environment, preferably FMCG.
• At least 3 years in a senior engineering management or supervisory role.
• Knowledge of the OHS Act and GMR 2.7 legal appointments.
• Knowledge of engineering principles and maintenance management systems (CMMS, SAP PM).
• Experienced in preventative maintenance plans and overall equipment effectiveness.
• Sound understanding of contractor management, project management and management of change.
• Ability to influence a large department and experience in managing poor performance.
• Computer literacy in SAP, MS Office (Word, Excel, Outlook, Projects), SharePoint and Corrective Action Systems.

Competencies:

• Excellent communication, presentation, negotiation, interpersonal and influencing skills
• Leadership and Team player
• Concern for standards
• Thorough and attention to detail
• Ability to work under pressure and deliver results
• Highly Analytical and Innovative
• Critical thinking, problem-solving and decision-making skills
• Professionalism, Personal Ethics, Loyalty and Values driven

Additional Requirements:

• Must be able to work overtime
• Must be able to be flexible and available as and when required
• Must be able to perform any other reasonable duties as and when required
• Must be able to stand-in for line manager when not available