Requirements
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.
Description
Position DetailsJob Title-Mechanical Manager – MaintenanceDepartment-Engineering / MaintenanceReports To-GM-OperationsDirect Reports-Mechanical Engineers, Shift Supervisors/Foremen, Fitters & Technicians,Location-Manufacturing Plant, EgyptGrade / Level-Middle to Senior Management2. Job PurposeTo 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.3. 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.4. 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 / Frequency1.Equipment Reliability & Plant AvailabilityOverall 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 CompliancePM schedule adherence %; Number of unplanned breakdowns/months; Ratio of planned vs breakdown maintenance man-hoursPM adherence = 100%; Breakdowns reduced by 20% YoY; Planned: Breakdown ratio ≥ 80:203.Maintenance Cost & Budget ControlMaintenance cost as % of production cost/turnover; Budget variance %; Cost per unit of outputWithin approved annual budget (±5%); Cost/unit trending down YoY04.Safety, Health, Environment (SHE) & Statutory ComplianceLost 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 ManagementCritical spares availability %; Inventory turnover ratio; Dead/obsolete stock valueCritical spares availability = 100%; Inventory value within budgeted norms; Dead stock < 2% of inventory value6.Manpower Development & Team ManagementTraining man-hours per technician/year; multi-skilling index; Team attrition rateMin. 40 hrs training/technician/year; 2+ skills per technician; Attrition < 10% p.a.7.Energy & Resource EfficiencySpecific energy consumption (kWh/ton or equivalent); Utility leakage (steam/air/water) audit closureReduction of 3–5% YoY in specific energy consumption; Leakage audit actions closed within 15 days8.Capex Projects & Equipment UpgradationOn-time project completion %; Project cost variance %; post-commissioning performance vs designOn-time completion ≥ 90%; Cost variance within ±10%; Performance meets design within 30 days of commissioning9.Documentation, MIS & CMMS RecordsTimely 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 ManagementOn-time delivery of spares/services; Vendor performance rating; Contractor safety complianceOn-time delivery ≥ 95%; Vendor rating ≥ 4/5; Zero contractor safety violations