Plant Maintenance Manager

We are seeking an experienced and results-driven Maintenance Manager (Electrical and Mechanical) to oversee and lead the maintenance operations of our Gypsum boards, Profiles and readygips manufacturing plant. This role is critical to ensuring the smooth operation of machinery and systems, minimizing downtime, and enhancing overall plant efficiency.

What you ll be doing:

• Develop and implement a comprehensive maintenance strategy for all electrical, mechanical and power plant systems in the manufacturing plant.
• Manage Electrical and Mechanical maintenance services in Gypsum Powder plant, Plaster board plant, Pastose product mixing and grinding plant, Profiles plant, Gas and Diesel Power Plants.
• Oversee the maintenance and repair of production machinery, Mill, mixers, dryers, and other critical equipment.
• Lead the mechanical maintenance team by providing guidance, instruction, direction, and leadership to the team, whilst achieving a safe working environment & optimal equipment technical availability.
• Monitor and manage maintenance schedules to ensure minimal downtime and maximum operational efficiency.
• Follow advanced methods on Preventive and Predictive maintenance techniques and analysis for equipment availability, reliability, cost efficiency and enhance operational safety.
• Spare parts management Manage the inventory of spare parts and maintenance tools, (electrical, mechanical and power plant) for production plants and ensuring availability when needed.
• Standardising maintenance tasks, applying CI techniques and investigating new technologies in maintenance, continually improve the performance of the maintenance team in line with the strategic plan to attain world class maintenance standards.
• Collaborate with the production and engineering teams to address equipment-related challenges.
• Develop department objectives, plan development and performance review of all team members in the maintenance department.
• Ensure compliance with health, safety, and environmental regulations.
• Identify and implement improvement opportunities to optimize machine performance and reduce operational costs.
• Prepare and monitor maintenance budgets, ensuring cost-effective operations and keep up to date with emerging technologies and trends in maintenance and manufacturing.
• Execute CAPEX projects and/or assist project sub-teams involved in process and product optimization, innovation, cost reduction, or other related business activities.

What we d love for you to have:

We are interested in you as a person: your attitude, behaviors and values. As long as you have the willingness to learn anything you need for the role that you don't already have, we'd love to speak to you. If you have experience in the following areas this is an added advantage:

• Bachelor's degree in mechanical engineering, electrical engineering, or a related field.
• Minimum of 10+ years of experience in maintenance management, preferably in the gypsum or similar manufacturing industry.
• Strong expertise in both electrical and mechanical systems, including PLCs, motor control systems, power generation plants and HVAC systems.
• Familiarity with SAP / CMMS (Computerized Maintenance Management Systems) is a plus.

Technical Skills:

• Knowledge in Programmable Logic Controllers (PLCs) used in automation systems for gypsum production lines and proficiency in maintaining and troubleshooting electric motors, variable frequency drives (VFDs), and motor control centres (MCCs).
• Knowledge of high-voltage and low-voltage electrical systems, transformers, and power distribution networks and skills in ensuring compliance with electrical safety standards.
• Familiarity with sensors, actuators, and other instrumentation used in gypsum manufacturing processes and ability to calibrate and maintain control systems for accurate production metrics.
• Proficiency in diagnosing and repairing hydraulic and pneumatic systems, which are critical in gypsum manufacturing.
• Experience with predictive maintenance techniques, such as vibration analysis and thermal imaging etc. and ability to identify underlying causes of equipment failures and implement corrective actions.
• Knowledge of industry-specific safety standards, including lockout-tagout (LOTOTO) procedures and machine guarding.
• Familiarity with environmental standards related to gypsum manufacturing, such as dust control and emissions monitoring. Preparedness for handling emergency maintenance situations safely and efficiently.
• Ability to read and interpret blueprints, schematics, and technical drawings for machinery and systems and skills in analysing operational data to identify inefficiencies and plan maintenance interventions.
• Ability to inspire, manage, and mentor a diverse team of technicians and engineers.
• Commitment to upskilling team members and fostering a learning-oriented environment.
• Competence in designing and implementing long-term maintenance strategies to enhance reliability and efficiency.
• In-depth understanding of gypsum production processes, including calcination, forming, drying, and packaging.
• Proficiency in identifying and implementing measures to enhance machine efficiency and reduce operational costs.
• Thorough understanding of safety and environmental regulations applicable to gypsum manufacturing.
• Ability to work closely with production, quality, and supply chain teams to align maintenance with operational goals. Ability to adapt to changing priorities, such as urgent breakdowns or shifts in production demand.
• Strong communication skills to liaise with vendors, suppliers, and senior management effectively.
• Proficiency in managing maintenance projects, from routine overhauls to large-scale upgrades and ensuring projects are completed within deadlines and with minimal disruption to production.
• Commitment to ethical practices in maintenance operations and vendor interactions.
• Focus on implementing environmentally sustainable maintenance strategies.