Maintenance Manager

Responsibilities:

1. Leadership & Team Management

Lead, coach, and develop the maintenance and facilities team, including external contractors.

Align maintenance and production goals with plant productivity, quality, safety, and cost objectives.

Drive team accountability and performance via KPIs and structured performance reviews.

Coordinate cross-functional communication with Production, QA/QC, R&D, and Safety.

2. Maintenance Operations & Strategy

Plan, schedule, and execute preventive, corrective, and predictive maintenance activities.

Maintain detailed breakdown reporting and lead root‑cause analysis (RCA) for recurring failures.

Implement condition‑based maintenance practices using machine data and performance trends.

Oversee machine calibration, lubrication, alignment, and safety compliance.

3. Industrial Engineering & Process Analytics

Analyse machine cycle time, downtime, availability, and efficiency (OEE).

Monitor performance data and develop actionable improvement plans to increase machine utilisation.

Identify bottlenecks and opportunities to reduce cycle time and improve throughput.

Optimise cookie production flows: mixing → forming → baking → cooling → packing.

Conduct time & motion studies for dough preparation, tray handling, and packaging (flow wrap, tray pack, tin pack).

Set standard cycle times, manpower norms, and batch sizes.

Work with production to optimise workflows and reduce waste.

4. Continuous Improvement & Lean Manufacturing

Champion 3S/4S/5S workplace organisation and visual management practices.

Lead Lean initiatives: Kaizen, SMED, Value Stream Mapping.

Reduce downtime, excess inventory, waiting time, and overbaking losses.

Drive efficiency improvement projects and best practices in standard maintenance routines.

5. Manpower Planning & Analysis

Suggest manpower allocation based on machine condition, workload, and production schedules.

Develop staffing plans aligned with plant demand, preventive cycles, and high‑critical equipment.

Adjust workforce deployment dynamically to mitigate downtime risks.

6. Equipment & Layout Planning

Plan factory layout for new cookie lines, automation upgrades, and packaging expansions.

Collaborate with suppliers on dough mixers, wire-cut/rotary moulders, tunnel ovens, cooling conveyors, and packing machines.

Ensure optimal material flow and machine accessibility for production efficiency and hygiene.

7. Spare Parts & Vendor Management

Maintain optimal spare parts inventory, monitor usage, lead times, costs, and reorder levels.

Evaluate and manage service contracts with OEMs and external technicians.

Ensure vendor compliance with quality, safety, and delivery requirements.

8. Budgeting, Reporting, Compliance & Food Safety

Develop, manage, and track maintenance budgets and capital expenditures.

Prepare periodic performance reports, dashboards, and maintenance forecasts.

Ensure compliance with food industry regulations, safety standards, GMP, HACCP, ISO 22000, and FSSC 22000.

Maintain accurate documentation of work orders, maintenance logs, and equipment histories.

Design hygienic plant layouts and optimise material flow to minimise contamination risk.

Reduce cross-contamination, especially for allergens such as milk, nuts, and eggs.

Optimise metal detection and check-weigh systems for product safety and efficiency.

To report any risks or any evidence of unsafe or out-of-specification product, equipment, packaging or raw materials to the Director / Executive Director to enable the resolution of issues requiring immediate action.

To perform ad hoc tasks assigned by the superior / management from time to time.

Requirements:

Candidate must possess at least a Bachelor’s Degree in Industrial Engineering, Mechanical Engineering, or a related field.

Minimum of 5 years’ experience in maintenance or operations, preferably in a manufacturing environment.

Experience managing teams responsible for production automation, equipment maintenance, and plant systems.

Excellent communication, interpersonal, leadership, and problem-solving skills, including root-cause analysis.

Proficient in CMMS, ERP, MES, Excel, statistical analysis tools, and general computer applications.

Knowledge in computer usage, including AutoCAD drawing, email, PowerPoint presentation, Excel data analysis, and report writing.

Able to work independently with minimum supervision and well-equipped with a multi-tasking ability.