Mechanical Manager – Maintenance

Position Details

Job Title-Mechanical Manager – Maintenance Department-Engineering / Maintenance Reports To-GM-Operations Direct Reports-Mechanical Engineers, Shift Supervisors/Foremen, Fitters & Technicians, Location-Manufacturing Plant, Egypt Grade / Level-Middle to Senior Management

1. Job Purpose

To plan, organize, direct, and control all mechanical maintenance & installation activities of the plant machinaries so as to maximize equipment reliability and plant availability, minimize breakdowns and maintenance cost, and ensure a safe, compliant and efficient operating environment, in line with the company's production, quality, safety and cost objectives.

1. Key Responsibilities

• Develop and implement the annual mechanical maintenance plan (preventive, predictive and corrective) for all plant equipment including reactors, agitators, pumps, compressors, blowers, gearboxes, piping and Utilities.
• Lead breakdown maintenance and root-cause analysis (RCA) to eliminate repeat failures and improve equipment reliability.
• Prepare and manage the annual maintenance budget; monitor and control maintenance spend, spares consumption and contractor costs against budget.
• Ensure availability of critical spares through effective inventory planning, in coordination with the stores/procurement function.
• Drive Preventive Maintenance (PM), Total Productive Maintenance (TPM) and reliability-centred maintenance (RCM) practices across the plant.
• Ensure full compliance with statutory and regulatory requirements (Thermic Fluid heaters, Reactors,Barton reactor,smelter,and lifting equipment, electrical safety) applicable in Egypt.
• Own plant safety for all mechanical maintenance work — permit-to-work systems, lock-out/tag-out (LOTO), job safety analysis, and contractor safety compliance.
• Plan and execute capex projects, equipment upgrades, revamps and shutdowns/turnarounds within budget and schedule.
• Lead, train, appraise and develop the maintenance team; build a multi-skilled, motivated workforce.
• Coordinate with Production, Quality, EHS, and Procurement departments to align maintenance activities with plant operating priorities.
• Evaluate, select, and manage external vendors and service contractors for equipment maintenance, overhauls and spare parts supply.
• Maintain accurate equipment history, maintenance records and CMMS/SAP-PM data; generate periodic MIS reports for management.
• Identify and implement energy conservation and cost optimization initiatives within the maintenance function.
• Support internal/external audits (ISO, safety, customer, statutory) related to mechanical maintenance and equipment integrity.

1. Key Result Areas (KRA) & Key Performance Indicators (KPI)

The table below summarizes the primary KRAs against which performance in this role will be measured, along with the associated KPIs and targets.

# Key Result Area (KRA) Key Performance Indicator (KPI) Target / Frequency 1.Equipment Reliability & Plant Availability Overall Equipment Effectiveness (OEE); Plant/Line Availability %; Mean Time Between Failures (MTBF); Mean Time to Repair (MTTR) OEE ≥ 85%; Availability ≥ 95%; MTBF improved YoY; MTTR ≤ 4 hrs (critical assets) 2.Preventive & Predictive Maintenance Compliance PM schedule adherence %; Number of unplanned breakdowns/months; Ratio of planned vs breakdown maintenance man-hours PM adherence = 100%; Breakdowns reduced by 20% YoY; Planned: Breakdown ratio ≥ 80:20 3.Maintenance Cost & Budget Control Maintenance cost as % of production cost/turnover; Budget variance %; Cost per unit of output Within approved annual budget (±5%); Cost/unit trending down YoY 04.Safety, Health, Environment (SHE) & Statutory Compliance Lost Time Injury (LTI) frequency rate; Safety audit non-conformance closure %; Statutory inspection compliance (pressure vessels, boilers, cranes, lifting tackles, electrical) Zero LTI; NC closure within 30 days = 100%; Statutory compliance = 100% 5.Spare Parts & Inventory Management Critical spares availability %; Inventory turnover ratio; Dead/obsolete stock value Critical spares availability = 100%; Inventory value within budgeted norms; Dead stock < 2% of inventory value 6.Manpower Development & Team Management Training man-hours per technician/year; multi-skilling index; Team attrition rate Min. 40 hrs training/technician/year; 2+ skills per technician; Attrition < 10% p.a. 7.Energy & Resource Efficiency Specific energy consumption (kWh/ton or equivalent); Utility leakage (steam/air/water) audit closure Reduction of 3–5% YoY in specific energy consumption; Leakage audit actions closed within 15 days 8.Capex Projects & Equipment Upgradation On-time project completion %; Project cost variance %; post-commissioning performance vs design On-time completion ≥ 90%; Cost variance within ±10%; Performance meets design within 30 days of commissioning 9.Documentation, MIS & CMMS Records Timely submission of daily/weekly/monthly maintenance MIS; Equipment history/CMMS record update % MIS submitted per schedule = 100%; CMMS records updated in real-time, accuracy ≥ 95% 10.Vendor & Contractor Management On-time delivery of spares/services; Vendor performance rating; Contractor safety compliance On-time delivery ≥ 95%; Vendor rating ≥ 4/5; Zero contractor safety violations

Education: B.E./ B.Tech in Mechanical Engineering.

Experience: 10–15 years of experience in mechanical maintenance, preferably in a chemical/manufacturing plant .

Technical Expertise: Strong experience in preventive, predictive and breakdown maintenance of reactors, agitators, pumps, compressors, gearboxes, piping and utilities .

Leadership & Compliance: Proven experience in leading maintenance teams, managing budgets, shutdowns, CAPEX projects, contractors, and ensuring LOTO, PTW, statutory and safety compliance .

Communication: Fluent English communication skills (written and verbal) with strong coordination and team-management abilities.