Maintenance Manager - Moulding

ResMed Inc.; New South Wales; On-site; AUD 130,000 - 180,000; Full time

Job summary

ResMed Inc. is seeking a Maintenance Manager - Moulding to lead maintenance, tooling, calibration, and reliability across moulding operations. You will drive uptime, implement preventive and predictive programs, and partner with Production, Engineering, Quality, and Manufacturing teams to ensure uninterrupted operations.

You will coach and develop maintenance staff, apply root cause analysis, and champion continuous improvement initiatives within GMP-regulated manufacturing environments.

Qualifications

• Bachelor's degree in a technical discipline is required.
• 8+ years in maintenance/manufacturing engineering or moulding operations.
• Experience managing maintenance for moulding equipment and plant machinery.
• Strong preventive/predictive maintenance knowledge and RCA methods.
• Experience with calibration systems, maintenance documentation, and regulatory compliance.

Responsibilities

• Lead maintenance for moulding operations to maximise uptime and performance.
• Develop and improve preventive, predictive, and corrective maintenance programs for moulding machines and tooling.
• Oversee maintenance, repair and optimization of moulding tools and plant equipment.
• Ensure calibration activities are documented and compliant with requirements.
• Collaborate with Production, Engineering, Quality, and Manufacturing teams to ensure uninterrupted operations.

Skills

Maintenance leadership

Root cause analysis

Process optimization

Stakeholder management

Communication

Education

Bachelor's Degree in Mechanical/Electrical/Industrial Engineering

Tools

CMMS

Calibration systems

Regulatory documentation

Quality systems

Job description

The Maintenance Manager - Moulding is responsible for leading the maintenance, tooling, calibration, and equipment reliability functions within the moulding manufacturing environment. This role ensures optimum performance, availability, and continuous improvement of moulding production equipment, tooling systems, and plant assets to support operational goals, production efficiency, quality standards, and regulatory compliance.

The incumbent will develop and implement maintenance strategies, oversee preventive and corrective maintenance programs, manage equipment calibration systems, and collaborate with Production, Engineering, Quality, and Manufacturing teams to ensure uninterrupted operations. The role also provides leadership, coaching, and technical guidance to maintenance personnel while driving operational excellence and continuous improvement initiatives.

Key Responsibilities

Maintenance & Equipment Reliability

• Lead the maintenance function for moulding operations, ensuring maximum equipment uptime, reliability, and performance.
• Develop, implement, and continuously improve preventive, predictive, and corrective maintenance programs for moulding machines, tooling, and supporting plant equipment.
• Oversee the maintenance, repair, and optimization of moulding tools, machinery, auxiliary equipment, and manufacturing systems.
• Ensure equipment calibration activities are completed, documented, and maintained in accordance with company and regulatory requirements.
• Monitor equipment performance metrics and implement corrective actions to minimize downtime and improve operational efficiency.
• Establish root cause analysis processes and drive resolution of recurring equipment and process issues.

Manufacturing Process Improvement

• Determine, develop, and implement methods, procedures, and best practices to optimize manufacturing processes and equipment performance.
• Partner with Production, Engineering, and Quality teams to identify opportunities for process improvements, cost reduction, waste elimination, and productivity enhancement.
• Support equipment upgrades, new equipment installations, process validations, and continuous improvement initiatives.
• Lead troubleshooting activities for complex manufacturing and maintenance challenges.

Leadership & People Management

• Provide day-to-day leadership, direction, and support to maintenance technicians and technical staff.
• Coach, mentor, and develop team members to enhance technical capabilities and performance.
• Conduct performance discussions and provide input into employee evaluations, development plans, and recognition programs.
• Foster a culture of accountability, teamwork, safety, and continuous improvement.
• Lead cross-functional teams and collaborative projects involving multiple departments.

Operational & Strategic Management

• Support the development and execution of strategic and operational objectives aligned with organizational goals.
• Ensure effective deployment of maintenance resources to meet production schedules and changing business demands.
• Collaborate with internal stakeholders, including Manufacturing, Quality, Supply Chain, Engineering, and Operations leaders to achieve business objectives.
• Drive initiatives that improve asset utilization, maintenance efficiency, and manufacturing effectiveness.

Quality, Safety & Compliance

• Ensure compliance with Quality Management Systems, Good Manufacturing Practices (GMP), Occupational Health & Safety (OH&S), and relevant regulatory requirements.
• Promote a strong safety culture and ensure adherence to all environmental, health, and safety policies.
• Support internal and external audits and ensure maintenance documentation is complete, accurate, and audit-ready.
• Maintain compliance with equipment qualification, calibration, and maintenance records.

Qualifications & Experience

Required

• Bachelor's Degree in Mechanical Engineering, Electrical Engineering, Manufacturing Engineering, Industrial Engineering, or a related technical discipline.
• Minimum 8 years of experience in maintenance, manufacturing engineering, moulding operations, or a related manufacturing environment.
• Proven experience managing maintenance activities for moulding equipment, tooling, and plant machinery.
• Strong knowledge of preventive and predictive maintenance practices, equipment reliability, and root cause analysis methodologies.
• Experience with equipment calibration systems, maintenance documentation, and regulatory compliance requirements.
• Demonstrated ability to analyze complex technical problems and implement effective solutions in the absence of established precedent.
• Strong leadership, coaching, communication, and stakeholder management skills.
• Experience working within GMP-regulated or highly regulated manufacturing environments is preferred.

Preferred

• Experience in medical device, pharmaceutical, automotive, or high-volume manufacturing industries.
• Knowledge of Lean Manufacturing, Six Sigma, TPM (Total Productive Maintenance), or Continuous Improvement methodologies.
• Familiarity with computerized maintenance management systems (CMMS).
• Project management experience involving equipment installation, upgrades, and process improvement initiatives.