Maintenance à United States

MAINTENANCE MANAGER

Reporting to

Chief Operating Officer(COO)

Overall role

The Maintenance Manager in the operation phase of a PV, Battery Energy Storage System (BESS), and Internal Combustion Engine (ICE) power plant is responsible for managing all maintenance activities to ensure the reliability, efficiency, and safety of generation and transmission assets. Reporting directly to the COO, the Maintenance Manager oversees preventive, corrective, and predictive maintenance programs, leading the maintenance team to achieve high availability of assets and minimize downtime. This role requires expertise in asset management, team coordination, and adherence to regulatory and safety standards, supporting the plant’s operational and strategic goals.

Working place

Kingdom of Saudi Arabia – Tabuk province - Al Wajh area

Key responsibilities and tasks

1. Maintenance Strategy and Planning

Development of Maintenance Programs

• Design and implement comprehensive maintenance programs for PV, BESS, ICE, and transmission assets, including preventive, corrective, and predictive maintenance.
• Develop maintenance schedules that balance operational requirements with equipment reliability, ensuring minimal disruption to power generation and storage.
• Establish maintenance goals and KPIs in alignment with operational objectives, aiming to reduce unplanned downtime, enhance asset lifespan, and optimize costs.

Preventive and Predictive Maintenance Planning

• Lead the planning of preventive maintenance schedules, ensuring that all assets are regularly inspected, serviced, and calibrated according to OEM recommendations.
• Implement predictive maintenance strategies, using data-driven insights (vibration analysis, thermography, oil analysis) to anticipate equipment failures and plan interventions.
• Collaborate with the Performance & Reliability Engineer to identify trends in equipment performance, adjusting maintenance schedules based on asset condition and usage.

Maintenance Resource Allocation

• Allocate resources, including personnel, tools, and spare parts, to ensure all scheduled maintenance tasks are completed effectively and on time.
• Work with procurement and inventory teams to maintain an adequate stock of critical spare parts and consumables, reducing lead times for repairs.
• Develop contingency plans for resource reallocation during peak maintenance periods or emergencies, ensuring operational continuity.

2. Team Leadership and Development

Team Supervision and Performance Management

• Lead a team of maintenance supervisors, technicians, and support staff, providing guidance, direction, and performance feedback to ensure team members meet quality standards.
• Set clear performance expectations and conduct regular evaluations, addressing any skill gaps and providing support for team members to excel in their roles.
• Promote teamwork and foster a positive work environment, encouraging open communication, collaboration, and accountability.

Training and Skill Development

• Identify training needs within the maintenance team, working with HR to coordinate technical training, safety workshops, and certification programs.
• Ensure that all maintenance personnel are trained on the latest procedures, tools, and safety standards, particularly for high-voltage equipment and energy storage systems.
• Implement a cross-training program to build versatility within the team, enabling technicians to work across PV, BESS, and ICE assets as needed.

Succession Planning and Leadership Development

• Identify high-potential employees for key maintenance roles and create clear career paths with advancement opportunities.
• Mentor supervisors and lead technicians to build their leadership skills and prepare them for increased responsibilities.
• Foster an environment where all team members are encouraged to contribute ideas for enhancing maintenance practices.

3. Maintenance Execution and Asset Management

Supervision of Maintenance Activities

• Oversee all maintenance activities, ensuring that tasks are performed in accordance with established procedures, safety standards, and quality requirements.
• Coordinate with the Operations Manager to schedule maintenance tasks around operational priorities, minimizing impact on power production.
• Conduct regular site inspections to verify that maintenance work meets quality and safety standards, addressing any deviations immediately.

Coordination of Corrective Maintenance

• Respond to equipment failures or malfunctions promptly, coordinating corrective maintenance efforts to restore asset functionality with minimal downtime.
• Collaborate with shift teams and on-site personnel to diagnose issues, arrange necessary repairs, and implement solutions efficiently.
• Document corrective actions taken and review incident data to identify root causes and prevent recurrence.

Equipment and Asset Health Monitoring

• Monitor the health of all assets, using data from SCADA and condition monitoring tools to assess the performance of PV, BESS, and ICE systems.
• Work closely with the Performance & Reliability Engineer to track asset performance metrics, identify equipment aging, and plan for replacements or upgrades as needed.
• Maintain a detailed asset register and maintenance history, supporting effective lifecycle management and reliability-centered maintenance.

4. Safety and Compliance

Safety Standards and Protocols

• Enforce strict adherence to safety protocols, including Lockout/Tagout (LOTO), use of Personal Protective Equipment (PPE), and hazard control measures.
• Ensure that all maintenance tasks, particularly those involving high-voltage equipment and BESS, are performed in a safe manner, minimizing risks to personnel.
• Conduct safety audits within the maintenance team, identifying and correcting any unsafe practices or conditions.

Regulatory Compliance

• Ensure that all maintenance activities comply with local and national regulatory standards, including those related to environmental protection, health, and safety.
• Prepare for and support external inspections or audits, providing necessary documentation and demonstrating compliance with all regulatory requirements.
• Work with the HSE team to implement safety and environmental standards specific to PV, BESS, and ICE assets, including emissions control and waste management practices.

Incident Reporting and Investigation

• Lead investigations for any maintenance-related incidents, documenting findings, and implementing corrective actions to prevent future occurrences.
• Ensure that all incidents, near-misses, and safety observations are reported accurately and addressed in a timely manner.
• Collaborate with the HSE Manager to review incident reports and adjust maintenance practices to enhance safety and reduce risk.

5. Budgeting and Cost Control

Maintenance Budget Management:

• Develop and manage the maintenance department’s budget, aligning expenditures with operational needs and financial objectives set by the COO and CFO.
• Monitor maintenance costs, including labor, materials, and contracted services, identifying cost-saving opportunities while maintaining quality standards.
• Report budget performance regularly to the COO, highlighting any variances and recommending adjustments to meet financial targets.

Cost Optimization Initiatives:

• Optimize spare part use, extend asset life with preventive maintenance, and reduce energy consumption.
• Identify and implement improvements to reduce maintenance overhead without impacting reliability.
• Collaborate with procurement to secure cost-effective deals for parts, tools, and services.

Spare Parts and Inventory Management:

• Collaborate with the Warehouse Supervisor to maintain the right stock of critical spares while controlling costs.
• Adjust inventory based on maintenance schedules, anticipated repairs, and asset aging.
• Regularly review practices to ensure efficient spare part usage and responsible disposal of obsolete items.

6. Reporting and Communication

Maintenance Reporting to COO:

• Prepare and present reports to the COO summarizing asset health, completed tasks, incidents, and KPI performance.
• Communicate major activities, challenges, and resource needs to keep senior management informed.
• Provide data-driven insights and recommend improvements to boost operational efficiency.

Root Cause Analysis and Documentation

• Lead RCA for major failures, document findings, and implement preventive actions.
• Ensure up-to-date and accurate records for tasks, repairs, and parts to support asset management.
• Collaborate with the Reliability Engineer to document data for long-term maintenance planning and asset optimization.

Internal and External Communication:

• Align maintenance with operations, engineering, and HSE to support broader operational and safety goals.
• Serve as the main point of contact for external contractors, overseeing their work to meet plant standards.
• acilitate regular meetings with the maintenance team and other stakeholders to review priorities and progress.

Pre-requisites

Educational and Experience Requirements

• Education: Bachelor’s degree in Mechanical, Electrical, or Industrial Engineering, or a related technical field.
• Experience: 10+ years of experience in maintenance management, with at least 5 years in a leadership role within power generation or industrial settings.
• Certifications: Certifications in maintenance and reliability, such as Certified Maintenance & Reliability Professional (CMRP) or equivalent, are advantageous.

Technical Skills

• Asset Management and Maintenance Planning: Expertise in developing maintenance strategies and managing comprehensive preventive and predictive maintenance programs.
• Technical Knowledge: Deep understanding of PV, BESS, ICE, and transmission systems, with proficiency in using SCADA and diagnostic tools for condition monitoring.
• Data Analysis and Reporting: Skilled in analyzing performance data to improve maintenance practices, reduce downtime, and make informed asset management decisions.