Planned Maintenance Leader

Job Title:

Planned Maintenance Leader

Reports to:

Maintenance & Engineering Manager

Department:

Diego Martin Plant

Date:

July 2014

Purpose:

• To lead the planning and execution of all planned maintenance activities for production equipment and to support the execution of planned maintenance activities for plant utilities.Additionally, to assist with the identification, development and implementation of operational, maintenance and engineering project-based solutionswhich are related to optimization of production equipment efficiency and performance.

Business Results Which Are Directly Affected By Your Individual Performance:

• Lost Time Incident Frequency/Severity
• Line Productivity
• Line Delay
• Line Waste
• First Time Quality

• Compliance to Production Schedule
• Customer Complaint Frequency
• Material Usage Variance
• Cost/ Case
• Gross Profit

Direct Reports:

Dotted Line Reports:

• None

• Maintenance Technicians
• Operator-Technicians

Core Areas of Operational Knowledge, Skill and Competence:

On-Boarding Qualifications and Experience:

• Product Design and Specifications
• Product Manufacturing Processes
• Equipment design, function and capability
• Equipment failure troubleshooting and analysis

• HSSE Policies, Standards and Procedures
• GMP and HACCP Standards

• Production Make-Ready Procedures

• Minimum MEET or EEET certification. (A BSc. Degree in Mechanical or Electrical Engineering would be preferred.)
• Minimum of 15 years of experience in the field of a maintenance and engineering.
• Minimum of 5 years of experience in a supervisory capacity within the field of maintenance and engineering.

Core Talents:

Striving Talents

Thinking Talents

Relating Talents

• Achiever
• Kinesthetic
• Competition
• Competence
• Mission
• Service
• Ethics
• Focus
• Discipline
• Arranger
• Work Orientation
• Gestalt
• Responsibility
• Performance Orientation
• Strategic Thinking
• Problem Solving
• Creativity
• Empathy
• Interpersonal
• Individualized Perception
• Developer
• Stimulator
• Team
• Persuasion
• Command
• Activator
• Courage

Work Schedule:

• Forty (40) hours over five (5) consecutive days, which may include Saturdays and Sundays. Additional hours, call-out hours as required by project or operational demands.

Main Responsibilities:

Expectation

Responsibilities

Performance Measure

Any condition which presents a hazard to the health or safety of employees must be addressed with urgency and to the full extent that is feasible.

• To guarantee the safety of production employees during the operation of production equipment, by leading the identification and elimination of equipment-related safety hazards.
• To identify, in conjunction with the EHS Officer, immediate and longer-term solutions for identified hazards and to enlist the support of necessary personnel (whether internal or external) for timely implementation of the solutions.
  • Number of LTI’s
  • Number of reported incidents
  • Total number of lost man-days

If a line experiences equipment failure, there must be urgent response for corrective maintenance.

• To support equipment failure troubleshooting efforts when on site and remotely so as to ensure minimized unplanned downtime and efficient execution of corrective repairs.

• Effective Downtime %

When a line experiences equipment failure, especially on the first shift, decisions must be made in a timely manner to either pursue an alternative process flow or reassign labour.

• To quickly liaise with production leaders following assessments of failure and determination of time to repair such that timely decisions may be made on the need to temporarily pursue an alternative process for continuation of the production run or reassign labour.

Production schedules must be completed as planned so as to ensure service level satisfaction.

• To monitor the execution of line changeovers and equipment set-up activities for scheduled production runs, so as to ensure adherence to defined procedures.
• To proactively communicateany possible risks to the timely satisfaction of production schedules so that contingency plans can be developed.

• Weekly Master Schedule Attainment

More time must be spent by technical team members on planned activities which prevent failures than on firefighting of unplanned failures.

• To lead the development and implementation of preventive maintenance programs for all manufacturing lines. This includes:
• To lead the timely and effective execution of planned corrective or preventive maintenance activities for manufacturing lines.
• To ensure that critical spare parts listings are developed for all manufacturing lines and that the adequate stock is always maintained.
• To ensure the availability and controlled usage of all monitoring and testing equipment necessary for execution of preventive maintenance inspections.
• To routinely review the inspection records to ensure the effectiveness of the PM program and to identify the need for short term interventions or longer term engineering modification of equipment.
  • Maintenance cost per case

• Routine inspection plans
• Routine cleaning, tightening, adjustment and lubrication plans
• OEM guided and experientially developed, replacement schedules
• Annual overhaul and rebuild schedules

Expectation

Responsibilities

Performance Measure

Continuous improvement of manufacturing processes and line efficiencies must become a rooted component of our culture.

• To support project-based activities including:

• The analysis of equipment modes of failure/lost time such that preventive plans may be improved or engineering modifications pursued for improved equipment reliability.
• The identification, development and implementation of engineering solutions aimed at improving product processing, filling and packaging efficiency.
• The identification, development and implementation of engineering solutions aimed at reducing operational waste.
• The development of equipment operation, process control and troubleshooting training programs.

• Total cost per case

Prevention of material losses must be a visible priority.

• To work with Production Supervisors and maintenance personnel in identifying and implementing engineering solutions which minimize loss of material during production.
  • Raw and Packaging Material Variances

No product which presents a known or perceived risk to consumer or customer satisfaction must be released to the market.

• To consistently review online product attributes and quality control records so as to define equipment capability and ensure adherence to defined product quality standards.
• To immediately support the analysis of product non-conformances such that appropriate corrective actions may be identified and implemented.
  • Number of Customer Complaints
  • First-pass yield

All operations reporting must be consistently accurate and timely

• To ensure that any routine or non-routine reports requested by the Production or Plant Manager are completed accurately and on-time.

The work environment must be one characterized by discipline, respect and productivity.

• To support the development and execution of reward and recognition programs which are geared toward the improvement of employee morale.

• To support the functions of the Maintenance and Engineering Manager when he is out of office.
• To perform any other related duties as guided by the Plant Manager or Maintenance and Engineering Manager