Maintenance Manager Plant, Material Handling & Power Generation Equipment
full-time
Overall Role Purpose
To ensure the reliability, availability, safety, and cost-effective maintenance of all plant, material handling and power generation equipment, including forklifts, reach stackers, top loaders and generators, through effective maintenance planning, asset management, team leadership, financial control and compliance with safety and regulatory requirements.
Key Responsibilities
Fleet Maintenance and Reliability
Design, implement and track comprehensive preventative maintenance schedules for all forklifts and top loaders based on hour intervals and operational cycles.
Oversee complex troubleshooting and repairs of heavy diesel engines, hydraulic lifting systems, high-capacity mast/spreader assemblies, transmission systems, and electrical/electronic controls.
Analyse equipment telemetry and performance data to identify breakdown trends and proactively address structural or mechanical failure before it disrupts operations.
Team Leadership and Operations
Lead, mentor and evaluate a team of heavy equipment mechanics and auto-electricians, assigning daily work orders and managing shift schedules.
Establish and enforce Standard Operating Procedures (SOPs) for safely servicing high-tonnage lifting equipment.
Ensure maintenance staff are continuously trained on specialized tools, hydraulic safety, high-voltage electric forklift batteries, and computer-aided diagnostics.
Safety, Compliance and Risk Management
Maintain strict compliance with local workplace health and safety laws (e.g., OSHA, or regional equivalents) regarding lifting equipment certifications.
Conduct routine inspections of maintenance bays, tooling, and rigging gear to enforce a zero-accident work environment.
Partner with operations to monitor fleet management to ensure only certified personnel operate the machinery and look after the equipment while under their control.
Inventory and Financial Control
Optimize stock levels for critical, high-wear components (e.g., hydraulic seals, hoses, spreaders, tires, filters) to avoid extended downtime.
Develop and monitor the annual maintenance budget, controlling expenditures on parts, lubricants, tools, and outsourced labour.
Core Competencies
Mechanical Mastery: Deep understanding of high-pressure hydraulics, heavy-duty diesel drivetrains, air brake systems, and electronic control systems.
Software Literacy: Proficiency utilizing Computerized Maintenance Management Systems to manage work orders, costs and inventory.
Physical Capability: A hands-on approach with the ability to safely navigate industrial yards, climb heavy machinery ladders, and inspect components under varying weather conditions.
Leadership: Exceptional communication, problem-solving under pressure, and cross-departmental collaboration skills.
Knowledge and Skills Required
Strong knowledge of heavy equipment, material handling equipment and power generation systems.
Sound understanding of preventive, predictive and reliability-centered maintenance practices.
Knowledge of hydraulic, diesel, electrical and electronic control systems.
Experience using Computerized Maintenance Management Systems (CMMS).
Strong budgeting, cost control and financial analysis skills.
Ability to lead technical teams and manage multiple priorities.
Strong reporting, communication and stakeholder management skills.
Knowledge of safety regulations, compliance standards and equipment certification requirements.
Qualifications
Bachelor's degree in Mechanical Engineering, Electrical Engineering, Automotive Engineering, Industrial Engineering or related field.
Professional maintenance or reliability certification (CMRP, CMP or equivalent) is an added advantage.
Minimum 8 to 10 years' experience in maintenance management within heavy equipment, logistics, manufacturing, port operations or industrial environments.
Proven experience managing forklifts, reach stackers, top loaders, generators and other critical operational assets.
Demonstrated success in improving equipment reliability, reducing downtime and controlling maintenance costs.
Experience leading technical teams and managing third-party service providers.