Senior Executive - Maintenance

Beckers Group is a privately-owned global coatings company and the market leader in coil coatings, as well as a leading supplier in industrial coatings for over 160 years.
With a strong sustainability focus (“raising the standard of care for our world”) and operations in 17 countries, Beckers emphasises innovation, quality, and long-term partnerships. (beckers-group.com)

The Senior Executive - Maintenance is responsible for maintenance and reliability of reactors, dispersers, mixers, pumps, compressors, chillers, utilities, filling lines, weighing systems and associated plant infrastructure, by implementing an effective preventive & predictive maintenance program which focuses towards reducing the downtime, repair cost and overall site maintenance cost. Close coordination with EHS department, investigating the risks and incidents and helping to close the Safety observations reported. This role requires strong analytical skills, ownership, negotiation, technical expertise and a commitment to continuous improvement.

Specific Responsibilities Include:

• The profile plays a crucial role in maintaining the safety of the site & installed machinery by implementing routine monitoring & preventive maintenance program in place.
• Lead and develop maintenance technician and contractors, to follow regulations stated as part of BLPS regulations, ensuring competency, safety compliance and effective execution of maintenance activities.
• Keep track of maintenance budgets, optimize maintenance expenditure and engage suppliers to ensure cost-effective procurement of services and spare parts.
• Downtime of the core or supporting equipment will impact the productivity of the internal function as well as the maintenance team. A well-developed Preventive Maintenance calendar/plan considering based on the equipment’s health and criticality will help the site to perform better.
• Develop inspection calendar for maintenance team to perform daily/weekly/monthly and review the observations with Manager.
• Spare/consumables required for equipment/site uptime is critical, better planning to maintain these inventories based on the lead time, requirement & cost based on the site condition is must.
• Calibration remains critical for the site to operate, Develop calibration calendar for critical weighing and filling measurement systems.
• Monitor the regular energy consumption pattern from the dashboard & installed meters, develop measures to conserve or reduce the consumption against requirement.
• Monitor the regular water consumption pattern from the dashboard & installed meters, develop measures to conserve or reduce the consumption against requirement.
• Identify and implement effective Computerized Maintenance Management System (CMMS) to maintain equipment history, work orders, preventive maintenance schedules and spare parts records.
• Lead root cause analysis (RCA), corrective and preventive actions (CAPA) and reliability improvement projects to eliminate recurring equipment failures.
• Building a good cross functional relationship with internal and external team is essential, which enables the path to learn & maintain the site up to date.

Integrated Management System (IMS) Responsibilities:

• Recognize and observe IMS policy.
• Comply with integrated management system (IMS) policy to improve work process.
• Comply and implement the controls required to mitigate the risks involved in the workplaces and surrounding areas.
• Implement EHS and Energy Operational controls in the workplace.

Relevant Training and Experience

• Bachelor’s degree in Mechanical engineering.
• Minimum 5 years of maintenance experience in Paints, Coatings, Chemical, FMCG, or Process Manufacturing Industries.
• Experience managing utilities and plant infrastructure.
• Knowledge of TPM, Reliability Engineering, RCA, FMEA and Preventive Maintenance Systems.
• Experience with SAP PM or equivalent CMMS.

Key Skills, Knowledge and Behaviors Required

• Proven ability to troubleshoot, maintain and repair a variety of manufacturing equipment to minimize downtime.
• Familiarity with safety standards, compliance protocols and best practices in a manufacturing setting.
• Proficient in using maintenance tools, diagnostic equipment and relevant software for record-keeping and reporting.
• Strong communication and team management skills with the ability to supervise and train junior maintenance staff.
• Ability to read and interpret technical drawings, machinery manuals and maintenance documentation.

Performance Monitors

• Mean Time Between Failures (MTBF)
• Mean Time to Repair (MTTR)
• Overall Equipment Effectiveness (OEE)
• Preventive Maintenance Compliance (PMC)
• Site Maintenance Cost
• Machine Maintenance Cost
• Inventory - SparesUnplanned down time

The above list is not exhaustive and the role holder may be required to perform reasonable additional duties.

This job description records the principal responsibilities of the job at the date shown. The job description will be updated from time to time in conjunction with the post holders to reflect changes.