Senior Manager, Plant Maintenance
BASIC FUNCTION OF THE JOB:
- Lead a high-performing Plant Maintenance organization to ensure the reliability, availability, safety, compliance, and optimal performance of all manufacturing equipment, automated production systems, utilities, facilities, and plant infrastructure at AO VSIP 1.
- Provide strategic leadership for Equipment Maintenance and Facilities teams to drive asset reliability, business continuity, and operational excellence.
- Develop and implement preventive, predictive, and reliability-centered maintenance (RCM), lifecycle management, spare parts optimization, and continuous improvement initiatives to maximize equipment uptime and Overall Equipment Effectiveness (OEE).
- Modernize maintenance capabilities by adopting advanced technologies, automation, digitalization, AI-enabled predictive maintenance, smart diagnostics, and condition monitoring.
- Build and develop team capabilities to support increasingly advanced manufacturing technologies and align maintenance practices with industry best practices.
- Collaborate closely with Engineering, Manufacturing, Quality, EHS, contractors, equipment service providers, and suppliers to proactively manage asset risks, infrastructure readiness, technology upgrades, and long-term asset replacement strategies.
- Build a scalable, future-ready maintenance organization that supports safe, reliable, efficient, and sustainable operations while enabling business expansion, long-term growth, and manufacturing excellence
- Leadership, Supervision & Organization Development
- Build, lead, coach, and develop the Equipment Maintenance and Facilities teams to deliver stable and sustainable performance.
- Ensure the maintenance organization is adequately staffed, trained, engaged, and empowered to maintain production equipment, utilities, facilities, and critical plant systems.
- Execute performance management, employee development, succession planning, recruitment, coaching, and communication activities effectively and on schedule.
- Foster a culture of open communication, accountability, safety, quality ownership, customer focus, and employee engagement.
- Maintain clean, safe, and organized work areas while serving as a role model for ethics, professionalism, leadership, technical competence, and business performance.
2. Business Operations, Budget & Governance
- Prepare and manage annual budgets for maintenance, spare parts, utilities, facility services, projects, and equipment replacement or upgrades.
- Establish and monitor department KPIs, including OEE, equipment uptime, MTBF, MTTR, preventive maintenance (PM) compliance, utility availability, maintenance cost, energy consumption, and project delivery.
- Ensure maintenance records, reports, performance metrics, and documentation are accurate, controlled, and submitted on time.
- Ensure maintenance and facilities processes comply with ISO 9001, ISO 13485 (where applicable), ITAR/Export Compliance, SOX, Quality, EHS, and corporate procedures.
- Review and continuously improve maintenance processes using Lean, Six Sigma, Process Value Chain, and continuous improvement methodologies to increase efficiency and reduce cycle time.
3. Manufacturing Equipment Maintenance & Reliability
- Lead day-to-day maintenance activities for all manufacturing equipment to ensure safe, reliable, and efficient operations with minimal downtime.
- Develop, implement, and sustain preventive, predictive, and corrective maintenance programs for production equipment, automation systems, and supporting equipment.
- Drive equipment reliability improvements using Root Cause Analysis (RCA), Failure Mode and Effects Analysis (FMEA), MTBF, MTTR, OEE analysis, Total Productive Maintenance (TPM), risk assessment, 5 Whys, and permanent corrective actions.
- Optimize maintenance planning, work scheduling, maintenance system utilization, repair quality, and maintenance execution effectiveness.
- Develop and implement spare parts strategies to ensure the availability of critical components while minimizing excess inventory and overstock.
- Support new equipment selection, installation, qualification, handover, upgrades, capacity expansion, and equipment lifecycle replacement planning.
4. Facilities, Utilities & Site Infrastructure Management
- Design, maintain, repair, and improve plant facilities, building infrastructure, utility systems, and production support equipment.
- Ensure reliable operation of HVAC, chillers, cleanrooms, air compressors, vacuum systems, RO/DI water systems, wastewater treatment, HT/LT electrical systems, fire protection, BMS, and SCADA systems.
- Maintain required environmental and utility conditions, including temperature, humidity, water quality, compressed air, vacuum, electrical power, fire safety, and environmental controls for production areas.
- Manage contractors, vendors, consultants, and service providers for equipment installation, relocation, modification, preventive maintenance, calibration, inspection, and handover activities.
- Ensure contractor work complies with technical specifications, building codes, safety requirements, manufacturer guidelines, statutory regulations, and approved schedules.
- Maintain system documentation, operating procedures, work instructions, calibration schedules, shutdown checklists, security support, and housekeeping standards.
Educational Background: Bachelor’s or Master’s degree in Industrial Engineering, Automation, Mechanical/ Electrical Engineering, or related fields.
Working Experience:
- 10+ years of experience in maintenance, engineering, facilities, or a manufacturing support environment.
- 5+ years of leadership experience managing engineering or maintenance organizations.
- Experience in regulated manufacturing and cleanroom operations.
- Experience managing utility systems, facility infrastructure, and production equipment.
- Proven experience leading capital projects and managing contractors.
- Strong knowledge of automation, PLCs, programming, and current industry best practices/market benchmarks.