MAINTENANCE MANAGER

1. ROLE PURPOSE

Ensure that production assets, utilities and supporting infrastructure are safe, compliant, reliable and cost-effective throughout their life cycle, enabling stable production and quality while continuously reducing operational risk and total cost of ownership.

2. KEY RESPONSIBILITIES

Maintenance Strategy & Governance

• Develop a 3–5 year reliability roadmap, annual operating plan and monthly maintenance priorities aligned with business, production, quality and EHS objectives.
• Establish and maintain maintenance policies, standards, workflows, service levels and escalation procedures.
• Apply risk-based priorities covering safety, product quality, legal compliance, production continuity, environmental impact and cost.

Asset Management

• Ensure accurate asset master data, including asset ID, location, ownership, criticality, technical specifications and maintenance strategy.
• Lead asset criticality assessments and review them following major changes or failures.
• Develop asset renewal, refurbishment, obsolescence and end-of-life plans, including repair-versus-replace and total cost of ownership analysis.

Maintenance Planning & Scheduling

• Implement a disciplined work-order process from request, planning and scheduling through execution, verification, closure and history capture.
• Maintain a risk-ranked maintenance backlog with required manpower, duration, permits, parts, tools and production access identified before scheduling.
• Lead weekly maintenance scheduling and daily coordination with Production to protect approved maintenance windows.

Preventive, Predictive & Condition-Based Maintenance

• Develop and optimise PM/PdM programmes based on manufacturer requirements, statutory obligations, asset criticality, failure history and operating conditions.
• Deploy appropriate condition-monitoring techniques such as vibration analysis, thermography, oil analysis, ultrasound, motor-current analysis, alignment and thickness/corrosion monitoring.
• Review maintenance effectiveness and overdue work, adjusting maintenance intervals based on documented technical and risk assessments.

Breakdown Response & Reliability Improvement

• Lead structured responses to critical equipment failures, including safe isolation, incident coordination, temporary controls, repair quality and verified return to service.
• Lead root-cause analysis for significant, recurring or high-risk failures and implement corrective/preventive actions and design improvements.
• Ensure temporary repairs are risk-assessed, time-limited and followed through to permanent resolution.
• Analyse downtime, MTBF, MTTR, recurring failures and maintenance costs to identify reliability improvement priorities.
• Apply reliability methodologies such as FMEA, RCM and structured problem-solving.

Utilities, Infrastructure & Energy

• Ensure assigned utilities and infrastructure have adequate capacity, redundancy, preventive maintenance, inspection and contingency plans.
• Monitor reliability, consumption and losses of electricity, fuel, compressed air, water and other key utilities.
• Implement approved energy and utility efficiency improvement projects.

Spare Parts, Tools & Technical Procurement

• Establish equipment BOMs and risk-based minimum/maximum inventory levels for critical, insurance and consumable spare parts.
• Approve technical specifications and evaluate equivalent parts to prevent unauthorised substitutions, counterfeit parts and obsolete components.
• Control special tools, lifting accessories, testing equipment and repairable spare parts, including inspection, calibration, storage and traceability.

Quality, Documentation & Compliance

• Ensure maintenance processes are defined, controlled, measured and continuously improved in line with the company QMS and approved procedures.
• Maintain complete and traceable maintenance records, including work orders, inspection results, parameter changes, parts used, test results, failure codes, downtime and return-to-service authorisation.
• Participate in audits, management reviews, non-conformity investigations and corrective-action follow-up.

EHS & Legal Compliance

• Enforce requirements relating to energy isolation, work permits, machine guarding, electrical safety, hot work, lifting, confined spaces, working at height, chemical control and PPE.
• Stop unsafe work or equipment when necessary and lead technical actions to prevent recurrence.
• Ensure maintenance waste, oils, chemicals, batteries, electronic parts and replaced components are properly segregated, contained and transferred through approved channels.

People Leadership

• Design maintenance organisation and shift/on-call coverage according to asset risk and production requirements.
• Set objectives, coach performance, conduct evaluations and address underperformance.
• Maintain technical competency and authorisation matrices and close competency gaps through structured training.
• Develop succession plans and promote knowledge retention through standard work, mentoring and cross-training.

Budget & Cross-Functional Leadership

• Prepare and control operating and capital budgets based on asset condition, production requirements, risk and life-cycle cost.
• Forecast budget variances and implement corrective actions proactively.
• Work closely with Production, Quality, SHE, Engineering/Projects, Warehouse, Procurement, Finance, HR, IT and external service providers.

3. QUALIFICATIONS & EXPERIENCE

• Education: Bachelor’s degree or above in Mechanical Engineering, Electrical Engineering, Automation, Industrial Engineering or a related discipline.
• Experience: 7–10 years of progressive industrial maintenance/engineering experience, preferably in heavy manufacturing such as foundry, steel, metal processing or similar industries.
• Minimum 4–6 years of experience leading a multi-disciplinary maintenance team.
• Strong preference for candidates with experience in casting, steel or pipe manufacturing.
• Strong working knowledge of mechanical, electrical, instrumentation, automation, PLC, hydraulics, pneumatics and machine safety, with deeper expertise in at least one discipline.
• Proficient in CMMS and enterprise systems, with the ability to analyse work-order, downtime, maintenance cost, inventory and equipment-condition data.
• Practical knowledge of ISO 9001 and document control.
• English: Working proficiency for technical documents, supplier communication, audits and management reporting.
• Chinese: Nice to have.
• Preferred certifications in maintenance/reliability, 5S, Lean/Six Sigma, project management or energy management

 

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