Job Profile: Maintenance Manager

Department: Maintenance

Reports To: CEO

Job Summary

The Maintenance Manager is responsible for leading all maintenance activities to ensure maximum equipment reliability, production uptime, and operational efficiency. This role oversees preventive, predictive, and corrective maintenance programs while ensuring compliance with safety, environmental, and quality standards. The Maintenance Manager also drives continuous improvement initiatives, manages maintenance budgets, and develops a high-performing maintenance team.

Key Responsibilities

Maintenance Management

• Develop and implement preventive, predictive, and corrective maintenance programs.
• Ensure all production equipment, machinery, facilities, and utilities are maintained in optimal operating condition.
• Minimize equipment downtime and improve Overall Equipment Effectiveness (OEE).
• Lead emergency breakdown response and root cause analysis.
• Monitor maintenance KPIs and implement improvement plans.

Team Leadership

• Lead, coach, and develop Maintenance Engineers, Supervisors, Technicians, and Contractors.
• Plan manpower allocation and shift coverage.
• Conduct performance evaluations and competency development.
• Promote teamwork and a continuous improvement culture.

Equipment Reliability

• Develop equipment reliability strategies to improve machine performance.
• Analyze equipment failures using Root Cause Analysis (RCA), 5 Why, Fishbone Diagram, and Failure Mode and Effects Analysis (FMEA).
• Improve Mean Time Between Failures (MTBF).
• Reduce Mean Time To Repair (MTTR).

Preventive & Predictive Maintenance

• Establish preventive maintenance schedules.
• Implement predictive maintenance techniques such as:
• Vibration analysis
• Thermal imaging
• Oil analysis
• Ultrasonic inspection
• Ensure maintenance activities are completed according to schedule.

Budget & Cost Control

• Prepare and manage annual maintenance budgets.
• Monitor maintenance costs and identify cost-saving opportunities.
• Optimize spare parts inventory.
• Manage vendor contracts and maintenance service agreements.

Facilities & Utilities Management

Oversee maintenance of:

• HVAC systems
• Air compressors
• Electrical systems
• Water supply systems
• Fire protection systems
• Chillers
• Boilers
• Building facilities
• Wastewater treatment systems (where applicable)

Safety & Compliance

• Ensure compliance with OSHA, DOSH, environmental, and statutory requirements.
• Ensure compliance with ISO 9001, ISO 14001, ISO 45001, and IATF 16949 (if applicable).
• Conduct risk assessments and ensure Lockout/Tagout (LOTO) procedures are followed.
• Lead maintenance safety audits.

Continuous Improvement

• Lead Lean Manufacturing, TPM (Total Productive Maintenance), and Kaizen initiatives.
• Improve maintenance planning efficiency.
• Support automation and digitalization projects.
• Reduce maintenance-related production losses.

Project Management

• Manage equipment installation, relocation, and commissioning.
• Support production expansion projects.
• Coordinate machine upgrades and process improvements.
• Work closely with Production, Quality, and Manufacturing Engineering teams.

Documentation & Reporting

• Maintain maintenance records using CMMS (Computerized Maintenance Management System).
• Prepare weekly and monthly maintenance reports.
• Analyze maintenance KPIs and present findings to management.

Qualifications

• Bachelor's Degree in Mechanical Engineering, Electrical Engineering, Mechatronics Engineering, or a related discipline.
• 8–10 years of maintenance experience in a manufacturing environment.
• At least 3–5 years in a managerial or leadership role.
• Experience in automotive, electronics, metal stamping, injection molding, automation, or precision manufacturing is preferred.

Key Performance Indicators (KPIs)

• Equipment uptime (%)
• Overall Equipment Effectiveness (OEE)
• Preventive Maintenance compliance (%)
• Mean Time Between Failures (MTBF)
• Mean Time To Repair (MTTR)
• Maintenance cost vs. budget
• Breakdown frequency
• Spare parts inventory accuracy
• Safety incidents
• Energy consumption reduction