Maintenance Manager- PepsiCo South Africa x1
- Position: Maintenance Manager
- Company: PepsiCo South Africa
- Location: Bethlehem
- Facility: Bethlehem Mill
- Department: Supply Chain
Purpose of the Position
The Maintenance Manager is responsible for leading all engineering and maintenance functions within the mill to ensure maximum plant reliability, operational efficiency, and regulatory compliance. The role oversees preventive maintenance programs, engineering projects, equipment upgrades, maintenance budgets, safety compliance, and maintenance personnel.
The incumbent acts as the legally appointed engineering authority responsible for ensuring that plant equipment and operations comply with statutory regulations, including the Occupational Health and Safety Act (OHS Act) and Government Machinery Regulations (GMR 2).
Key Responsibilities
1. Plant Maintenance Management
Preventive and Planned Maintenance
- Develop and implement preventive maintenance strategies.
- Ensure all equipment receives scheduled maintenance.
- Minimize equipment downtime and production interruptions.
- Improve plant reliability and operational efficiency.
- Review and optimize maintenance schedules continuously.
Breakdown Management
- Lead investigations into equipment failures and plant breakdowns.
- Implement permanent corrective actions.
- Identify root causes and prevent recurring failures.
- Coordinate emergency maintenance activities.
Asset Reliability
- Monitor plant performance and reliability indicators.
- Develop asset management improvement plans.
- Ensure machinery operates safely and efficiently.
- Extend equipment lifespan through effective maintenance practices.
2. Engineering and Technical Leadership
Engineering Systems
- Manage maintenance records through SAP Maintenance Management Systems.
- Maintain accurate equipment information and maintenance histories.
- Optimize preventive maintenance schedules within SAP.
- Monitor engineering performance indicators.
Projects and Upgrades
- Lead plant improvement projects.
- Manage equipment upgrades and modernization initiatives.
- Support installation and commissioning of new equipment.
- Coordinate engineering contractors and service providers.
Technical Problem Solving
- Resolve complex engineering and mechanical failures.
- Provide technical leadership to engineering teams.
- Implement innovative engineering solutions.
- Improve production performance through technical enhancements.
3. Health, Safety and Environmental Compliance
Legal Compliance
- Ensure compliance with:
- Occupational Health and Safety Act (OHS Act)
- Government Machinery Regulations (GMR 2)
- Company safety standards
- Environmental regulations
Safety Management
- Conduct safety inspections.
- Ensure proper use of safety equipment.
- Promote a strong safety culture.
- Investigate safety incidents and implement corrective actions.
Environmental Management
- Monitor environmental compliance requirements.
- Support sustainable operational practices.
- Ensure responsible use of resources and energy.
4. Maintenance Team Leadership
Staff Management
- Lead and supervise maintenance personnel.
- Coordinate activities of artisans, technicians, and support staff.
- Conduct performance management and evaluations.
- Manage disciplinary matters when required.
Training and Development
- Develop annual training plans.
- Build technical competency within the maintenance team.
- Mentor and coach engineering staff.
- Ensure succession planning and skills development.
Workforce Planning
- Manage leave schedules and workforce availability.
- Allocate resources effectively.
- Ensure adequate staffing levels for maintenance activities.
5. Spare Parts and Inventory Management
Engineering Stores Management
- Ensure efficient management of engineering stores.
- Maintain critical spare parts availability.
- Monitor inventory levels.
- Ensure compliance with COSO audit requirements.
Inventory Optimization
- Reduce excess inventory.
- Improve stock accuracy.
- Support cost-effective procurement decisions.
- Monitor usage and consumption trends.
6. Budget and Cost Control
Maintenance Budget Management
- Develop and manage maintenance budgets.
- Control maintenance expenditure.
- Monitor overtime costs.
- Ensure maintenance activities remain within approved budgets.
Cost Optimization
- Improve maintenance efficiency.
- Reduce unnecessary repair costs.
- Monitor contractor expenditure.
- Ensure effective utilization of maintenance resources.
7. Reporting and Performance Monitoring
KPI Management
- Monitor and improve maintenance KPIs.
- Develop engineering performance reports.
- Present maintenance trends and recommendations.
- Track equipment availability and reliability.
Management Reporting
- Prepare monthly engineering reports.
- Compile maintenance performance dashboards.
- Present findings to senior management.
- Support operational decision-making through data analysis.
Minimum Requirements
Qualifications
Essential
- Technical Trade Qualification or National Training Certificate.
- National Diploma in:
- Electrical Engineering, or
- Mechanical Engineering.
- Government Certificate of Competency (GCC) – Mandatory.
Advantageous
- Bachelor of Engineering (BEng).
Experience
Essential
- Minimum 5 years maintenance experience in an FMCG environment.
- Minimum 3 years management experience.
- Experience managing engineering teams.
Advantageous
- Milling industry experience.
- Manufacturing plant maintenance experience.
Technical Knowledge Required
Engineering
- Mechanical systems.
- Electrical systems.
- Preventive maintenance.
- Asset management.
- Reliability engineering.
Systems
- SAP Maintenance Management.
- Inventory Management Systems.
- Microsoft Office Suite.
Regulatory Knowledge
- OHS Act.
- GMR Regulations.
- Environmental legislation.
- Safety management systems.
Required Competencies
Leadership Competencies
- Team leadership.
- Staff development.
- Performance management.
- Decision-making.
- Conflict resolution.
Technical Competencies
- Engineering problem-solving.
- Maintenance planning.
- Root cause analysis.
- Reliability improvement.
- Asset management.
Business Competencies
- Budget management.
- Cost control.
- Strategic planning.
- Operational management.
Personal Competencies
- Initiative and accountability.
- Analytical thinking.
- Resilience and endurance.
- Attention to detail.
- Results orientation.