The Maintenance Engineer is responsible for ensuring the optimal operational efficiency and reliability of all plant equipment, machinery, and facilities. This role involves developing and executing preventive maintenance programs, managing complex equipment repairs, troubleshooting mechanical and electrical issues, and leading continuous improvement projects to enhance safety, quality, and productivity. The engineer acts as a technical expert, minimizing downtime and extending asset life through effective maintenance strategies.
General Responsibilities
Maintenance Strategy & Execution
- Develop, implement, and manage Preventive Maintenance (PM) and Predictive Maintenance (PdM) schedules and procedures to maximize equipment uptime and minimize reactive maintenance.
- Lead the investigation and resolution of complex mechanical, electrical, hydraulic, and pneumatic faults on production machinery and utility systems.
- Utilize and manage the Computerized Maintenance Management System (CMMS) for work order tracking, asset history, and spare parts inventory control.
- Oversee and coordinate maintenance technician activities, ensuring all repairs and service work are completed safely and to high quality standards.
Reliability & Continuous Improvement
- Conduct Root Cause Analysis (RCA) for significant equipment failures and chronic issues, implementing permanent corrective actions.
- Identify opportunities for equipment upgrades, modifications, and process improvements to enhance reliability, efficiency, and reduce operational costs.
- Manage capital projects related to equipment replacement, facility expansion, and technology upgrades.
- Monitor key performance indicators (KPIs) such as Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR) and develop strategies to improve them.
Safety & Compliance
- Ensure all maintenance activities comply with local, state, and federal safety regulations (e.g., OSHA, environmental).
- Develop and enforce Lockout/Tagout (LOTO) procedures and other critical safety protocols.
- Conduct safety audits and risk assessments on new and existing equipment.
Inventory & Documentation
- Specify and manage critical spare parts inventory to ensure availability while optimizing inventory holding costs.
- Maintain accurate and detailed maintenance records, equipment schematics, and technical documentation.
Technical Skill Development & Training
- Assess Skill Gaps: Conduct regular technical competency assessments of maintenance technicians to identify individual and team skill gaps (e.g., PLC programming, complex equipment troubleshooting, precision alignment).
- Develop Training Content: Create and deliver high-quality technical training materials, including Standard Operating Procedures (SOPs), job aids, and hands-on modules, to address identified gaps.
- Mentor Technicians: Act as a technical mentor and coach to maintenance personnel, fostering a culture of continuous learning and technical excellence.
- Manage External Training: Coordinate with equipment vendors and external training providers to schedule specialized training sessions for new technologies or complex machinery.
Procedure Development & Documentation
- Standardize Work: Develop, author, and maintain clear, concise, and safe Maintenance Procedures, Standard Work, and LOTO (Lockout/Tagout) documentation for all critical assets.
- Audit Procedures: Periodically review and audit existing PM/PdM procedures for accuracy, effectiveness, and compliance with safety standards, updating them based on failure data and best practices.
- Technical Library Management: Ensure all equipment manuals, electrical schematics, and hydraulic drawings are properly archived and accessible to the maintenance team via the CMMS or a central repository.
Experience / Qualifications
A university degree required (i.e. Bachelors degree) or equivalent relevant work experience.
Problem-Solving: Exceptional analytical and troubleshooting skills under pressure.
Communication: Excellent written and verbal communication skills to interact with technicians, management, and vendors.
Instructional Skills: Demonstrated ability to develop and present technical training content to an adult audience with varying levels of experience.Documentation Proficiency: Proven ability to create professional, unambiguous technical documents, procedures, and reports.
Familiarity with Training Models: Experience with structured On-the-Job Training (OJT) programs, apprenticeship models, or technical skill matrices is highly beneficial.
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