Maintenance Manager, Ipoh Plant

The Company

Imerys is listed on Euronext Paris (France) with the ticker symbol NK.PA.

The Position

Maintenance Manager, Ipoh Plant

Job Summary

Improve plant and equipment operating efficiency by providing maintenance and engineering support to the plant operations. Generate cost estimates and required documentation for both capital and maintenance project approval and must complete projects on time at or under budget. Ensure safety and environmental compliance with corporate policies and government regulations. Develop the annual maintenance and capital project budgets. Supervise, develop, train, communicate with, and develop the team members in operational performance and skills needed to improve the reliability of the plant equipment.

KEY TASKS AND RESPONSIBILITIES
- Lead maintenance improvement initiatives identified through failure root cause analysis and /or compliance, growth, or cost reduction requirements.
- Ensure all maintenance objectives are completed on time and within budget.
- Assess and document success/failure of completed work orders.
- Establish preventive and predictive maintenance tasks for key process and support equipment.
- Establish work schedules to include lubrication, cleaning, and inspection routines.
- Supervise, develop, train, communicate with, and develop the engineer, fitters, and electricians in operational performance and skills needed to improve the reliability of the plant equipment and engage team to perform RCA of equipment failures to prevent recurrence
- Troubleshoot plant equipment failures and respond to emergencies of safety hazards and environmental regulation infractions to ascertain equipment optimization, personnel safety, and governing requirements of compliance.
- Develop standards for equipment to improve reliability, inventory control of critical equipment through specifications, but demonstrated procurement standards to ensure maximum operating hours for production equipment, quality of product, and on-time shipment for our customers.
- Continually improve the operational integrity of the equipment by reviewing failures, PM schedules, PDM strategies using condition monitoring technologies, and proper equipment optimization to reduce cost and improve production output.
- Managing the maintenance cost to be within budget and developing strategies to reduce the overall cost as well as inventory cost.
- Create and maintain a central database of equipment condition data to track performance trends and predict maintenance needs
- Establish and track KPIs to measure maintenance effectiveness (OEE, MTBF, RF, PM compliance)
- Lead the digital transformation of maintenance operations through implementation of IoT sensors, remote monitoring systems and collaborate with the IT department to ensure seamless integration between IT and OT (Industrial Scada and PLC)
- Evaluate and implement strategic outsourcing of specialized maintenance functions when beneficial while managing relationships with third-party maintenance contractors and OEMs
- Project Management and Capital Improvement
- Work closely with the management team to develop the capital budget for the plant. Prepare and submit plant improvement and major maintenance projects from estimating, scheduling, design, cost management, and commissioning to improve plant processes.
- Work closely with the Production Department to perform process performance testing, develop cost reduction projects, equipment improvement, and methods modifications.
- Develop and implement energy efficiency initiatives within maintenance operations to reduce consumption and environmental impact
- Provide ‘hands-on’ supervision and support during routine and project maintenance engineering tasks.
- All other tasks and duties as assigned
- To communicate safety alerts, lessons learned, and incident sharing on time to the department
- To ensure employees/contractors are well trained on their tasks
- To be accountable for employees/contractors' safety
- To intervene in any unsafe behavior at the site
- Encourage employees/contractors to conduct peer-to-peer safety observations
- To ensure all the operators & general workers are complying with EHS rules at all times
- To make sure ideas for improvement are acted upon and will coach their teams to develop competencies. Zero tolerance will be applied if our Serious 7 critical standards are breached. Managers relentlessly look for opportunities to reduce risk exposure and will never let production priorities compromise safety.

SAP Utilization:

- Implement and manage maintenance activities using the SAP Plant Maintenance (PM) module, including work order processing, preventive maintenance scheduling, and inventory control.
- Ensure accurate documentation of maintenance activities within SAP PM to facilitate data-driven decision-making and continuous improvement.

Crushing Plant and Ball Mill Expertise:

- Possess in-depth knowledge of crushing plant and ball mill operations, including ma