Kerja Sepenuh Masa, Maintenance - Engineering Manager di NPAworldwide Johor - Maukerja

Job Description

• Plant Maintenance Management
• Lead preventive, predictive, corrective, and breakdown maintenance for all glove production equipment.
• Develop and maintain an effectivePreventive Maintenance (PM) and Predictive Maintenance (PdM) program
• Ensure production equipment achieves required availability and reliability targets.
• Monitor recurring equipment failures and implement permanent corrective actions.
• Conduct root cause analysis for major breakdowns and repeat failures.
• Improve equipment reliability using failure analysis, condition monitoring, and maintenance history.
• Establish equipment maintenance standards, checklists, schedules, and inspection frequencies.
• Coordinate maintenance activities with Production to minimize production interruption.
• Ensure proper maintenance of glove dipping lines, chain systems, former holders, bearings, pumps, blowers, fans, conveyors, ovens, stripping systems, stacking systems, and packing-related equipment.
• Monitor mechanical, electrical, pneumatic, hydraulic, thermal, and instrumentation systems.
• Maintain critical spare-parts availability and establish minimum/maximum stock levels.
• Review obsolete and slow-moving maintenance inventory and control unnecessary spare-parts expenditure.
• Develop shutdown maintenance plans and coordinate annual or major plant shutdown activities.
• Utility Management
  
  

Responsible for reliable and efficient operation of plant utilities including:

• Electrical power distribution systems
• Transformers, switchboards and electrical protection systems
• Air compressors and compressed-air systems
• Chillers and chilled-water systems
• Cooling towers
• Pumps and water distribution systems
• Boilers where applicable
• Biomass heating systems
• Thermal-oil heating systems
• Hot-water systems
• HVAC and ventilation systems
• Exhaust and scrubber systems
• Process-water systems
• RO / water-treatment systems
• Wastewater-treatment supporting equipment
• Fire-fighting systems
• Generator and emergency power systems
  
  

Key Duties Include

• Ensure utilities are continuously available to support production requirements.
• Monitor daily energy, water, compressed-air and fuel consumption.
• Establish utility performance indicators such as kWh/1,000 gloves, water consumption/1,000 gloves, compressed-air efficiency and thermal-energy consumption.
• Identify and execute energy-saving and utility-cost-reduction projects.
• Investigate abnormal utility consumption and losses.
• Monitor compressed-air leaks, steam/thermal losses, water leakage and electrical losses.
• Optimize compressor pressure, pump operation, cooling-water temperature and other utility operating parameters.
• Maintain required standby equipment and emergency response plans for critical utilities.
• Ensure compliance with applicable Malaysian regulatory requirements including DOSH/JKKP, Energy Commission and other relevant authorities.

• Engineering Project Management
• Plan, coordinate and execute plant improvement, expansion and equipment installation projects.
• Prepare project scope, technical specifications, budget, schedule and manpower requirements.
• Prepare and evaluate CAPEX proposals.
• Conduct technical evaluation of vendors and contractors.
• Review quotations and provide technical recommendations to Purchasing and Management.
• Manage installation and commissioning of new production equipment.
• Coordinate civil, mechanical, electrical, piping, instrumentation and automation activities.
• Ensure projects are completed according to approved:
• Scope
• Budget
• Schedule
• Safety requirements
• Technical specifications
• Production requirements
• Conduct FAT, SAT and commissioning where applicable.
• Ensure proper equipment handover from Project to Maintenance and Production.
• Ensure drawings, manuals, spare-parts lists, PLC backups and technical documents are properly transferred after project completion.
• Monitor contractor performance and ensure safe working practices.
• Lead continuous-improvement and cost-saving engineering projects.
• Automation & Control Systems
• Lead plant automation improvement and equipment-control-system reliability.
• Maintain and improve PLC, HMI, SCADA, VFD, servo, sensors and instrumentation systems.
• Ensure proper backup and control of PLC/HMI programs.
• Troubleshoot automation, instrumentation and control-system failures.
• Improve automation of glove production processes to reduce manual intervention and process variation.
• Work with Production, Process and R&D teams to automate critical process controls.
• Identify opportunities for:
• Automatic dosing
• Temperature control
• Flow control
• Pressure control
• Chemical concentration monitoring
• Automatic inspection
• Machine interlocking
• Production data collection
• Alarm monitoring
• Energy monitoring
• Improve machine interlocks and safety control systems.
• Develop standard programming and automation practices.
• Maintain instrumentation calibration schedules.
• Ensure critical sensors, transmitters and control devices are properly calibrated and maintained.
• Support implementation of Industry 4.0, IoT, machine-data collection and production-monitoring systems where applicable.
• Glove Production Line Engineering Support
  

Provide Technical Support For Critical Glove Manufacturing Systems Including

• Latex / nitrile dipping tanks
• Coagulant systems
• Chemical dosing systems
• Former washing systems
• Former brushes and cleaning systems
• Former heating systems
• Leaching systems
• Dipping tanks
• Beading systems
• Curing ovens
• Thermal-oil heating systems
• Chain and conveyor systems
• Former holders
• Stripping systems
• Chlorination systems
• Polymer/coating systems
• Glove stacking systems
• Packing automation
  
  

Responsibilities Include

• Maintain stable mechanical and process-support conditions.
• Reduce equipment-related glove defects.
• Work with Production, QA, Process Control and R&D to investigate defects related to machine conditions.
• Improve production-line speed without compromising equipment reliability or product quality.
• Support line capacity improvement and cycle-time reduction.
• Eliminate equipment conditions contributing to pinholes, uneven dipping, glove damage, contamination and stripping problems.

• Reliability & Continuous Improvement
• Track equipment performance and reliability.
• Implement root cause analysis for major failures.
• Use maintenance data to identify recurring problems.
• Develop reliability-improvement programs.
• Apply engineering improvement methodologies such as:
• RCA
• 5 Why
• Pareto Analysis
• FMEA
• Kaizen
• TPM
• Predictive Maintenance
• Improve Mean Time Between Failure (MTBF).
• Reduce Mean Time To Repair (MTTR).
• Reduce emergency maintenance activities.
• Increase percentage of planned versus unplanned maintenance.
• Introduce condition-monitoring technologies such as:
• Vibration analysis
• Thermal imaging
• Motor-current monitoring
• Oil analysis
• Ultrasonic leak detection
• Maintenance Cost & Budget Control
• Prepare annual maintenance and utility budgets.
• Monitor monthly expenditure against approved budget.
• Control maintenance consumables and spare-parts costs.
• Review repair-versus-replacement decisions.
• Evaluate lifecycle cost of equipment.
• Negotiate and review maintenance service contracts.
• Identify opportunities for repair, refurbishment and local fabrication where technically appropriate.
• Prepare CAPEX justification for equipment replacement and major improvements.
• Spare Parts & Inventory Management
• Establish critical spare-parts lists for production and utility equipment.
• Define minimum and maximum inventory levels.
• Ensure critical spare parts are available before failure occurs.
• Review long outstanding and obsolete inventory.
• Monitor consumption trends.
• Standardize components where possible to reduce inventory.
• Ensure maintenance spare-parts records are accurate.
• Work with Purchasing to source reliable and cost-effective replacement parts.
• Safety, Compliance & Regulatory Requirements
• Ensure all maintenance and project work complies with company EHS requirements.
• Enforce Permit-to-Work procedures including:
• Hot work
• Confined-space entry
• Work at height
• Electrical isolation
• LOTO
• Ensure machinery guarding and safety interlocks are maintained.
• Participate in risk assessments and HIRARC activities.
• Ensure pressure vessels, lifting equipment, boilers and other regulated equipment are inspected and certified where applicable.
• Maintain statutory inspection and certification records.
• Ensure contractors comply with plant safety regulations.
• Investigate engineering-related safety incidents and implement corrective actions.
• Team Leadership & People Development
• Lead maintenance engineers, executives, supervisors, technicians and contractors.
• Establish clear responsibilities and performance expectations.
• Plan manpower according to production and maintenance requirements.
• Develop technical competency of maintenance personnel.
• Provide training in mechanical, electrical, automation, instrumentation and troubleshooting skills.
• Establish succession and development plans for key technical positions.
• Conduct employee performance reviews.
• Improve maintenance-team discipline and response effectiveness.
• Encourage troubleshooting based on analysis rather than temporary repair.
• Develop a culture of preventive maintenance and continuous improvement.
• Control overtime and manpower utilization.
  

Key Performance Indicators KPI

Recommended KPIs Include

Equipment Reliability

• Production line availability
• Equipment downtime
• MTBF
• MTTR
• Number of repeated breakdowns
• Breakdown hours per month
  
  

Preventive Maintenance

• PM completion rate
• Planned maintenance percentage
• Preventive vs corrective maintenance ratio
• Overdue maintenance jobs
  
  

Utility Performance

• Electrical consumption per 1,000 gloves
• Water consumption per 1,000 gloves
• Compressed-air consumption
• Thermal energy / fuel consumption
• Utility downtime
• Utility cost per 1,000 gloves
  
  

Project Performance

• Project completion on schedule
• Project completion within budget
• CAPEX utilization
• Project commissioning performance
• Cost savings generated
  
  

Automation

• Automation-related downtime
• PLC/control-system failures
• Number of successful automation improvements
• Manpower reduction through automation
• Process variation reduction
  
  

Cost Management

• Maintenance cost per 1,000 gloves
• Spare-parts inventory value
• Emergency purchase frequency
• Maintenance budget variance
  
  

Safety

• Maintenance-related accidents
• LOTO compliance
• Contractor safety compliance
• Statutory inspection compliance
  
  

Qualifications

Qualifications:

• Bachelor's Degree or Diploma in Mechanical Engineering, Electrical Engineering, Mechatronic Engineering, Automation Engineering or related discipline.
• Preferably 812 years of manufacturing maintenance experience, including supervisory or managerial responsibility.
• Experience in glove manufacturing, rubber, chemical, process manufacturing, FMCG or high-volume automated production is preferred.
• Strong knowledge of mechanical, electrical and automation systems.
• Experience with utility systems and plant engineering.
• Experience managing engineering projects and CAPEX.
• Familiarity with PLC, HMI, VFD, sensors and instrumentation.
• Knowledge of preventive, predictive and reliability-centered maintenance practices.
• Knowledge of Malaysian industrial safety and statutory requirements is preferred.
  
  

Required Competencies

Technical

• Mechanical engineering
• Electrical engineering
• PLC and automation
• Instrumentation
• Utility management
• Thermal-oil systems
• HVAC
• Compressed air
• Pumps and piping
• Energy management
• Preventive and predictive maintenance
• Reliability engineering
• Project management
• Root cause analysis
  
  

Management

• Leadership
• Strategic planning
• Budget management
• Problem solving
• Decision making
• Contractor management
• Team development
• Cross-functional coordination
• Communication
• Performance management
  
  

Working Relationships

Internal: Production, Process Control, R&D, QA, EHS, Purchasing, Warehouse, Finance, HR and Senior Management.

External: Equipment manufacturers, contractors, consultants, utility providers, government authorities, inspection bodies and engineering service providers.

Overall Scope of Authority

The Maintenance Manager is accountable for maintaining the plant's technical readiness and has authority to:

• Stop equipment considered unsafe for operation.
• Recommend equipment modification or replacement.
• Approve maintenance work according to established authorization limits.
• Recommend CAPEX and engineering improvements.
• Coordinate planned production shutdowns with Production Management.
• Establish technical maintenance and engineering standards.
• Evaluate contractor and supplier technical performance.
• Implement approved reliability, utility and automation improvement programs.
  
  

Why Is This a Great Opportunity

• Strategic Engineering Leadership Offers the opportunity to lead plant-wide maintenance, engineering operations, and technical teams in a high-volume manufacturing environment.
• Advanced Technical Exposure Provides extensive exposure to mechanical, electrical, automation, PLC, instrumentation, and industrial utility systems, strengthening multidisciplinary engineering expertise.
• Operational Excellence & Reliability Improvement Focuses on improving equipment reliability, reducing unplanned downtime, increasing production efficiency, and implementing preventive and predictive maintenance strategies.
• Engineering Projects & Cost Optimisation Provides responsibility for CAPEX projects, equipment upgrades, automation initiatives, energy efficiency improvements, and maintenance budget control, contributing directly to plant performance and cost savings.
• Career Growth & Manufacturing Impact Offers a broad leadership scope covering maintenance, utilities, project management, safety compliance, and team development, making it a valuable opportunity for experienced engineering professionals with 812 years of manufacturing experience seeking to advance their managerial careers.