Maintenance Planner

PepsiCo; Durban; On-site; ZAR 300,000 - 500,000; Full time

Benefits offered by this job

Equal Opportunity Employer

Growth and development opportunities

Job summary

PepsiCo in Durban is looking for a Maintenance Planner to enhance asset reliability and efficiency within their Prospection Plant Snacks. The role involves administering the maintenance planning system, developing maintenance schedules, ensuring data integrity, and implementing reliability engineering principles. The ideal candidate should have 3-5 years of experience in FMCG, proficiency in CMMS like SAP S4Hana, and strong problem-solving skills. You'll be part of a dynamic team aimed at continuous improvement and ensuring operational excellence.

Qualifications

• Minimum 3-5 years of industrial experience in a food manufacturing or FMCG environment.
• Strong knowledge of maintenance planning and preventive systems.
• Significant experience with CMMS including data integrity and analysis.

Responsibilities

• Maximize technical availability and asset reliability.
• Develop weekly maintenance plans aligned with production and quality.
• Ensure accurate equipment master data and work order management.

Skills

Maintenance planning

Reliability engineering

Data analysis

Problem-solving

Communication

Education

3-5 years industrial experience in food manufacturing or FMCG

Tools

SAP S4Hana

Microsoft Excel

Power BI

Job description

Overview

About PepsiCo

PepsiCo products are enjoyed by consumers more than one billion times a day in more than 200 countries and territories around the world. PepsiCo generated more than $79 billion in net revenue in 2021, driven by a complementary beverage and convenient foods portfolio that includes Lay’s, Doritos, Cheetos, Gatorade, Pepsi-Cola, Mountain Dew, Quaker, and SodaStream. PepsiCo's product portfolio includes a wide range of enjoyable foods and beverages, including many iconic brands that generate more than $1 billion each in estimated annual retail sales.

Guiding PepsiCo is our vision to Be the Global Leader in Beverages and Convenient Foods by Winning with PepsiCo Positive (pep+). pep+ is our strategic end-to-end transformation that puts sustainability and human capital at the center of how we will create value and growth by operating within planetary boundaries and inspiring positive change for planet and people.

In South Africa (SA), you will find our products across the region at breakfast, lunch, or dinner. At the gym or on the field. In the office or on the go. We refresh, restore, and rejuvenate our consumers all day, every day with our key brands including Simba, Lay's, Liqui Fruit and Bokomo range of cereals. PepsiCo SA employs more than 13,000 people across our three business divisions: Bakeries, Grains, Foods, Fruit, Snacks, Juice & Beverages. For more information, visit www.pepsico.com.

Responsibilities

What we're looking for: We’re looking for a Maintenance Planner based at our Prospection Plant Snacks. The Maintenance planner shall be under the general direction of the Maintenance Manager. The Maintenance planner responsibility is to maximise technical availability, asset reliability and planned maintenance effectiveness by administering the maintenance planning system, ensuring data integrity, driving analytical problem‑solving, and embedding reliability engineering principles. The role combines diligent PM system administration with leading reliability initiatives that reduce unplanned downtime, eliminate repeat failures, and strengthen maintenance strategy.

Accountabilities

Maintenance Planning & Scheduling

• Develop weekly Provisional and Confirmed maintenance plans aligned with Production, Quality, Utilities, and Safety requirements. Ensure weekly planning meetings follow the PeMM standard attendees and agenda.
• Build, maintain, and optimize 12‑month maintenance master plans, including estimated times, craft allocation, spares, seasonal shutdowns, A & B spares, and reactive forecasts based on previous years.
• Ensure all required labour, materials, contractor resources, permits, and safety pre‑checks are defined and ready before job execution.

CMMS Master Data & Work Order Management

• Ensure all work orders meet the PeMM Data Standard (correct type, activity, failure & cause codes, timestamps, long descriptions, statuses, priority). Drive ≥80% data quality improvement.
• Maintain accurate equipment master data, ensure new equipment is added with correct structures, FLOCs, maintenance plans, and classification aligned to CMMS playbooks.
• Track and control backlogs, ensuring:
  • WOs >30 days remain <1% of total backlog
  • Aged backlog <5% of weekly throughput

Maintenance Strategy & Preventive Programme Execution

• Convert OEM tasks into RCM/FMEA‑based maintenance plans, ensuring plans are reviewed annually and aligned to asset criticality.
• Ensure consistent execution of Preventive Maintenance, targeting ≥80% planned work compliance and supporting the reduction of reactive hours.
• Integrate Condition Monitoring tasks (lubrication, vibration, thermography, oil analysis, inspections) into the CMMS with correct intervals and routes.

Spares, BOMs & Inventory Coordination

• Build and maintain equipment Bills of Materials (BOMs) in CMMS ensuring ≥80% completeness and accuracy (location, quantity, part numbers).
• Ensure parts reservation for all planned work, use JIB shelves effectively, and conduct quarterly reviews of unused reserved parts.
• Support inventory team with criticality analysis, obsolescence reviews, MRP parameters, and ensuring spares meet Global IMA standards.

Reliability, RCA & Loss Analysis Support

• Facilitate the closure and tracking of Root Cause Analysis actions for all qualifying downtime events (≥4 hours for Beverages). Ensure RCA → CMMS linkage and verify action completion.
• Maintain structured Top Losses analysis for downtime, MTBF, MTTR, high cost items, high usage spares, and OEM performance. Support monthly maintenance scorecard updates.
• Ensure Work Orders include findings that inform updates to maintenance plans, intervals, or design changes.

Contractor & Service Provider Coordination

• Ensure contractor work is planned, scoped, and reviewed for quality. Capture all contractor labour hours and costs in the CMMS (≥75% required to score “At Standard”).
• Prepare job packs, risk assessments, permits, spares lists, and safe‑work criteria for contractor tasks.

EHS & Compliance‑Driven Maintenance

• Ensure 100% scheduling and tracking of all legislated inspections (lifting equipment, boilers, compressors, electrical HV/LV tests, fire systems) with ≥90% completion to target dates.
• Support GEHSMS implementation through maintenance‑driven compliance tasks (preventive inspections, walkdowns, Gemba).

Documentation & Knowledge Management

• Maintain updated technical SOPs, lubrication maps, ConMon checklists, task instructions, and ensure updates after RCAs or equipment modifications.
• Ensure correct storage and versioning of electrical drawings, PLC backups, and P&IDs, with traceable change control as required by PeMM.

KPI Reporting & Governance

• Track and report core PeMM KPIs monthly:
  • Unplanned downtime
  • Planned work compliance
  • Technician utilization
  • Reactive %
  • Stock value vs CARV
  • Training hours
  • Maintenance costs vs CARV
• Drive actions to move site from “Reactive/Moving to Control” toward “Innovative @ Standard.”

Continuous Improvement & Lean Maintenance Practices

• Lead or support improvement initiatives (lubrication optimization, ConMon deployment, A3s, MIAP actions, cost reduction projects, spares rationalization).
• Ensure PeMM recommendations are embedded into maintenance processes and governance routines.
• Participate in weekly, monthly, and period maintenance reviews with evidence‑based updates.

Qualifications

• Experience: Minimum 3–5 years industrial experience, preferably in a food manufacturing or FMCG environment.
• Maintenance & Reliability Expertise: Strong knowledge of maintenance planning, preventive systems, and PM optimisation.
• Significant experience with CMMS (SAP S4Hana/ Fiori) including data integrity, reporting, and analysis.
• Proven exposure to reliability methodologies: RCA, RCM/FMEA.

Data & Analytical Skills

• Ability to perform Pareto analysis, cost summaries, MTBF/MTTR reviews, lifecycle costing, and failure trend analysis.
• Demonstrated problem‑solving capabilities and data interpretation skills.

Computer Literacy

• High proficiency with standard software: Word, Excel, PowerPoint, Teams, Power Bi, and CMMS reporting tools.

Leadership & Influence

• Ability to train, influence and facilitate multidisciplinary teams.
• 2–3 years supervisory/management experience (direct or indirect) beneficial.

Soft Skills

• Strong communication, presentation, and decision‑making skills.
• Excellent organisational skills; ability to manage multiple workstreams.

Certifications (Preferred but Advantageous)

• Six Sigma Green Belt, analytical problem‑solving qualification.
• Formal certification in RCM / FMEA / PFMEA.

“PepsiCo is an Equal Opportunity Employer in line with the Employment Equity Act.