Maintenance Manager
Based at our manufacturing site in Kildare and reporting to the Site Manager, the Maintenance Manager will lead the site's maintenance and process optimisation functions, ensuring safe, efficient and reliable plant operation.
This role is responsible for managing reactive and preventative maintenance activities through internal teams, contractors and third-party service providers. The successful candidate will oversee maintenance planning and execution, drive equipment reliability and plant performance, and ensure compliance with maintenance processes, procedures and schedules.
In addition, the role will lead process optimisation initiatives across manufacturing operations, acting as the site Subject Matter Expert (SME) for key production processes and supporting the continuous improvement of plant performance, efficiency and product quality.
Key Responsibilities
Maintenance Leadership
- Ensure manufacturing equipment performance meets or exceeds agreed KPIs for availability, reliability and efficiency.
- Lead the site's maintenance strategy, driving a proactive Preventive and Predictive Maintenance culture.
- Manage the maintenance technician team, supporting performance, development and ongoing skills enhancement.
- Identify training requirements and support the continued development of maintenance personnel.
- Ensure all maintenance activities are completed in compliance with Health & Safety, Quality and GMP requirements.
- Maintain ownership of the site's Computerised Maintenance Management System (CMMS).
- Manage and control the Maintenance Department budget.
- Conduct periodic reviews of maintenance systems and implement continuous improvement projects focused on equipment performance and reliability.
- Apply best-practice maintenance strategies to sustain long-term improvements.
- Develop Project Initiation Requests (PIRs) and support the design and implementation of capital projects where required.
Process Improvement & Optimisation
- Lead end-to-end process and plant optimisation across production, filling and packing operations, utilities and raw material intake.
- Act as the site Process Subject Matter Expert, providing technical leadership and support for production-related issues.
- Establish process performance standards and drive continuous improvement across manufacturing operations.
- Troubleshoot operational issues and identify opportunities to improve plant performance and KPI delivery.
- Monitor and analyse MES and process performance data, providing trend analysis and actionable recommendations.
- Utilise data-driven insights to improve efficiency, quality and operational effectiveness.
- Partner with Production and Quality teams to prioritise, develop, test and implement process improvements.
- Utilise the relevant Change Control systems to secure approvals and manage the implementation of process changes.
- Support the planning and execution of approved operational improvements.
Documentation, Compliance & Training
- Own process-related documentation, including Standard Operating Procedures (SOPs), process documentation, logbooks and training materials.
- Complete Quality Management System documentation, including Change Controls, Event Reports and Root Cause Analysis (RCA) investigations.
- Lead Change Control activities for designated process areas.
- Support the development, planning and delivery of process and technical training programmes.
- Train and support employees on process management, automation systems and MES platforms.
- Assess and support the technical competency development of new and existing employees.
What We're Looking For
- Experience in a maintenance leadership, supervisory or senior engineering role within a food manufacturing, dairy, pharmaceutical or similar regulated manufacturing environment.
- Third-level qualification in Engineering, Science or a related discipline.
- Strong organisational, planning and prioritisation skills.
- Demonstrated knowledge and application of Root Cause Analysis (RCA) methodologies.
- Experience applying Lean Manufacturing, Six Sigma, Continuous Improvement or Process Improvement methodologies.
- Ability to analyse data, identify trends and develop solutions that improve operational performance.
- Strong technical capability with excellent attention to detail.
- Proven ability to engage and collaborate effectively with internal and external stakeholders.
- Results-focused with a customer-centric mindset and the ability to perform in a fast-paced manufacturing environment.
- Excellent communication, leadership and interpersonal skills, with the ability to influence and bring teams together to achieve common goals.
