Maintenance Engineering Manager

Role: Maintenance Engineering Manager

Location: Laois

Choice People are recruiting on behalf of our client for a Maintenance Engineering Manager, this is a senior position taking overall responsibility for the leadership and development of a high performance engineering team, and the embedding of high standard maintenance processes and practices within a highly automated 24/7 mozzarella cheese production and packing facility, including the efficient operation and maintenance of all associated utilities. Taking ownership and accountability for performance agreed Key Performance Indicators and leading continuous improvement in all aspects of plant maintenance and utility operation.

Accountable to:General Manager

Direct Reports: Maintenance Team Leaders, Automation Engineer and Maintenance Stores Co-ordinator

Indirect report: Multi-skilled Maintenance Engineers (Team of 13)

Key Relationships: Site Management Team, Team Leaders, Operations and Quality teams, Technical services and NPD, Finance Team, Central Engineering Team, Key Suppliers

Responsibilities:

Relationship Development

• As a member of the site leadership team adopt an approach of collaboration, cohesion and support. Ensure there is active participation in site decision making and objective setting
• Build positive relationships with other departments, utilising these positive relationships to assist delivery of results through your team, and provide support towards the success of other teams.
• Build and maintain strong relationships with Site Management, establishing two way communication and accurate provision of information to support the efficient running and continuous improvement of the site.
• Build an excellent working relationship with the Production team to ensure the Maintenance department deliver an excellent service to meet 24/7 operational uptime and operational efficiency targets through the implementation of an effective asset care program
• Work closely with the Food safety team to ensure that engineering work is completed in line with food safety guidelines and that issued are communicated effectively and an ethos of working together to overcome problems is encouraged.
• Through effective team leadership, promote a harmonious working environment based upon the building blocks of the company’s Vision and Values and take action to address individual or group behaviour that may be detrimental to positive working relationships in accordance with company procedures.
• Develop and maintain strong relationships with all functions including Health and Safety, Production, Food Safety & Quality, Technical Services, Planning, Finance, and HR.

Team Management & Development

• Leading, coaching and development of reporting engineers and team leaders to ensure capability to deliver current and future business objectives and encourage flexibility and cross functional skills, instilling a ‘fix it right first time’ attitude throughout the team.
• Identifying and arranging training for the department in line with the annual training budget for the department.
• Provide strong leadership to the Maintenance function to ensure there is effective support for the operations
• Provide a source of expertise to maintenance engineers on all matters related to plant and equipment. Coach and assist the engineers to decide on appropriate corrective action in breakdown situations with a view to enhancing their ability to make repeat decisions unaided when similar situations occur
• Introduce and monitor a set of key performance metrics to the department, which will support the growth and development of this newly established team
• Develop and embed a plan of regular communication and engagement, which supports a culture of proactive involvement
• Conduct well-structured Daily Management Systems (DMS) meetings & attend management DMS and planning meetings as required.
• Ensure all planned meetings are prepared for and actively encourage two way participation at these meetings, with timely follow up and close out of agreed action
• Guide the team leaders to ensure that PSOP’s capture the knowledge and experience of the team to manage all activities, processes and procedures and that these are used to train others on “one standardised way” of operating
• Promote an approach of problem solving and peer to peer learning within the department
• Coach and develop direct reports through regular one to ones, formal Performance review process and set and agree development plans
• Promote an effective cross functional team approach.
• In conjunction with HR take a lead role in the recruitment and employee relations processes within the department

Maintenance Operational Effectiveness

• Encourage a “go and see” attitude amongst the team when problems arise, and promote engagement with all appropriate colleagues e.g. production, quality and engineers to determine the actual root cause of the problem whilst at the scene of the problem.
• Oversee maintenance related action plans to address root causes to problems, ensuring action close outs are implemented and SOP’s and decision trees are updated appropriately. Ensure the quantity of work and quality of workmanship is maximised by all maintenance engineers and contractors.
• Ensure 24/7 maintenance cover across the site to ensure the execution of all PPM activity as per the work schedule. a

• Monitor the planned preventative maintenance systems for all areas including PPM schedules for all plant and equipment, management of data regarding machine breakdowns, fault analysis and update of PPM procedures through the use of KPIs, customer service levels, detailed planned and preventative maintenance schedules and condition monitoring techniques.
• Develop the use of the PPM system to enhance the benefits it can offer to the business.
• Ensure the maintenance of the building, environment and plant including heating, ventilation, fire protection equipment and plant, pipework and plumbing, ensure a safe working environment for colleagues and visitors.
• Ensure equipment operates at a standard in order to achieve the customer’s required product specification.
• Ensuring all issues of statutory inspections – including portable appliance testing, mains testing and pressure vessels, electrical thermo graphic etc are managed and records are maintained in line with current legislation.

• Co-ordinate and monitor effectiveness of mechanical and electrical sub-contractor labour

• The role requires the timely resolution of any site issues escalated to him/her and corrective action communicated promptly to all concerned. This corrective action will be reflected in appropriate decision trees to aid future decisions on similar issues

Strategy and Continuous Improvement

• Lead an effective culture of continuous improvement in all aspects of plant operations and maintenance
• Strategically develop, recommend and justify improvement plans for the site and the Maintenance department.
• Support a strategy for Engineering Maintenance that is in line with the overall strategic plans and values of the company
• Initiate and lead capital projects and the preparation of AFEs to support the site strategy
• Champion a high standard of quality in the engineering department at all times. Introduce initiatives which will develop and improve asset care awareness
• Lead and participate in operational and maintenance initiative to improve uptime and OEE using lean tools
• Through effective team management and plant monitoring, the Maintenance Manager will take a lead role in the daily review of plant performance against KPIs including OEE, yield and losses and use of 5 whys and DMAIC to identify and eliminate root causes of issues
• Developing and managing the annual budget for the maintenance department.

Responsible Care

• Drive and support a positive Health and Safety culture within the department where H&S is given equal priority with all other activities
• Maintain focus on workplace safety, ensuring all activities are carried out in accordance with Standard Operating Procedures (SOP’s), and that control measures are identified through comprehensive risk assessment and COSHH assessment.
• Ensure that the circumstances of any accidents or incidents are recorded in detail, reported via specified methods and that any supporting documentation is completed promptly.
• Promote the culture of “Stop, Think, Act” within the department. Observe, act on and immediately report any issues that may pose a threat to a safe working environment
• Encourage Maintenance Engineer engagement in safety tours and Gemba audits where risk assessment is a normal activity and hazard reduction/elimination is a key concern for all employees
• Promote the submission of Safety Improvement recommendation (SIR)’s
• Ensure all Personal Protective clothing and equipment is worn in accordance with company policy.
• Ensure all team members are fully aware of site H&S standards, and ensure production processes & maintenance activities operate in accordance with the requirements of ISO45001
• Assume responsibility for site personnel outside of normal office hours or during any emergency situation, e.g. fire evacuation as well as responsibility for the health, safety, welfare and supervision of all short/medium term non-company employees which you bring on to the site
• Educate Maintenance Engineers on the environmental and financial impacts of excess energy usage, detergents usage and material losses to drain
• Ensure all team members understand the Environmental Targets and objectives of the business and how their department can influence these in a positive manner.
• Ensure that accidental discharges are minimised, and where these may occur, that a spillage investigation report is completed and remedial action is implemented.
• Progressively raise the awareness of the whole team as to the cost drivers within the business Ensure awareness of site environmental standards and ensure that Production and utility processes operate in accordance with the requirements of ISO 14001 and the relevant Environmental Legislation
• Drive and support an effective quality culture within all areas of Maintenance
• Build quality checks into relevant maintenance tasks and roles which will identify quality issues at the earliest stage possible in the process

Person Specification

Qualifications and Training:

• Minimum 2nd class degree (or equivalent) in Mechanical / Electrical / Manufacturing Engineering
• Exposure to SAP PM
• Experience of training others on SAP PM
• 3 years recent and relevant experience of leading and managing a maintenance engineering team within a manufacturing environment
• Operating as part of a site leadership team, Experience in a food / dairy

manufacturing or pharmaceutical environment

• Understands the significance of SOP’s
• Able to demonstrate knowledge of how safe working practices are applied and how a safe place of work (SPOW) can be enhanced through operator inclusivity
• Evidence of having carried out Risk Assessments and hazard elimination
• Working knowledge of manufacturing operations and processes
• Detailed knowledge of manufacturing equipment, and of safety requirements in the maintenance and repair of same
• Evidence of having applied a structured problem solving approach

Key Relationships: Site Management Team, Team Leaders, Operations and Quality teams, Technical services and NPD, Finance Team, Central Engineering Team, Key Suppliers

Salary base 90-100k per annum

Bonus

Healthcare

Pension