Maintenance Manager - Kathu at Omnia (Pty) LTD

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.