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.