Maintenance Engineer

The qualities we look for 

Lipton Teas and Infusions is made up of a special blend of individuals which make our teams exciting and diverse. To be part of our tea family, whether for a short period or over the long term, we are looking for individuals who think Green and are environmentally conscious, who understand the power of simplicity and who are accountable for their actions. We want those who infuse mastery and passion in everything they do to create great products and unforgettable experiences for our consumers.

What's in it for you?

We believe that growth is for everyone; we believe in growing leaders who have an owner’s mentality. We believe in connections over hierarchies. We have a 'corporate start-up' approach; we act with speed and agility to tackle knotty business challenges.

We aim to build the future ready, value driven, transparent and real time supply chain ecosystem through disruptive digital transformation. We are seeking a team member with the passion to lead the pace of change, experience to create digital solutions and entrepreneurship to deliver business results.

Main Accountabilities:  Use experience and expertise to coach and guide assigned work of Maintenance Technicians within expected timelines to the quality required by spending a significant part of day on the shop floor (6/2 rule) – 75% of time on the floor and only 25% in meetings or administrative tasks. 

• Assess skills gaps and seek to close these through timely and appropriate training interventions. 
• Provide appropriate equipment and training to ensure safe working practices are upheld and environmental standards are adhered to. 
• Liaise with Maintenance Planner to ensure effective and efficient use of resources and accuracy of plan. 
• Ensure equipment is available to meet production plans by applying the Lipton Management System PM Methodology. 
• Validate standards applied by operators performing autonomous maintenance tasks and review with First Line Managers in production as necessary. 
• Review entries in the CMMS for accuracy and timeliness and take action where required. 
• Assess opportunities for continuous improvement in both preventive and predictive maintenance and build into ongoing plans. 

Safety: 

• Leading all Maintenance on site with compliance to site safety requirements 
• Developing and maintaining task registers for routine vs non-routine activities  
• Developing and maintaining Risk assessments for Routine activities   
• Closing all identified risks from risk prediction activities in ALL areas of the factory that fall under Engineering and Maintenance team 
• Key responsible for Machinery safety (supporting site competent person during handover and eventually assuming responsibility as site competent person) on the site 

Maintenance:  

• Plantwide breakdown analysis (Daily tracking and analysis of ALL breakdowns, Detailed root cause analysis for all TOP breakdowns, Implementation of corrective actions from analysis and actions coming out of all other teams (quality, safety etc)) 
• Responsible for complete factory maintenance, breakdowns and MTBF & MTTR KPIs 
• Reduction of Breakdowns in numbers and % contribution to OEE loss in packing (Developing Maintenance Plans, ensuring maintenance plans reach to component level, Executing planned maintenance activities and ensuring OTIF compliance, tracking maintenance compliance against breakdown reduction, Lead all major and minor modifications for OEE Improvement) 
• Reduction of Breakdowns in numbers and % contribution to OEE loss in making (approx. 800 Equipment e.g. valves, pumps etc) 
• Developing Maintenance Plans 
• Ensuring maintenance plans reach to component level  
• Executing planned maintenance activities and ensuring OTIF compliance 
• Tracking maintenance compliance against breakdown reduction  
• Lead all major and minor modifications  
• Reduction of Breakdowns in numbers and % contribution to OEE loss in Utilities (approx. 800 Equipment e.g. valves, pumps etc) 
• Initiating, Negotiating & Managing Annual maintenance contract for Utilities equipment  
• Ensuring all utilities equipment maintenance is done on time, in full  
• Lead all major and minor modifications  
• Selection and Maintenance of specific mechanical and electromechanical components 
• Able to analyze deterioration of different components with time, force, pressure, temperature, use etc 
• Able to provide basic design (including engineering drawings + P&ID) and selection of components based on process parameters, user requirements and usage conditions 
• Go into in depth analysis of failure modes of components 

Utilities: 

• Ensure day to day operations of all utility’s equipment 
• Drive maintenance agenda either through on-site technicians or AMCs 
• Drive projects to improve performance of utilities equipment or generate savings 

Automation and Digitalization: 

• Identify needs, understand and tabulate requirements  
• Give basic system design for automation projects  
• Calculate cost/benefit ratios 
• Lead automation projects for area of responsibility 

Cost: 

• Maintenance Cost tracking against volumes/other variables  
• Develop forecast models for all R&M Cost 
• Track FC vs Actual Weekly cost  
• Forecast R&M Budget in line with PM plans  
• Line wise breakup  
• Identify reduction opportunities in all cost (Utility + R&M + Manpower) to meet factory cost target year on year 

Lean Manufacturing or similar Management Systems e.g. TPM, Six Sigma, WCM 

• PM (Professional Maintenance) PILLAR LEADER 
• Core member of :
• AM (Autonomous Maintenance) 
• QA/QC (Quality Assurance/Control) 

Projects:

• Innovation projects  
• Capacity projects 
• Cost & Energy Saving projects 
• Focused Improvement projects 
• Various Maintenance and Infrastructure related projects  

 Skills and Experience: 

• Mechatronics/Electrical/Electronics/Mechanical Engineer with experience in Manufacturing and/or Maintenance  
• Able to demonstrate EXCELLENT engineering acumen – design and analysis of parts, machines, and systems using  
• 3D modelling software  
• AutoCAD 
• FEA (finite element analysis methods) 
• Theoretical data for machine & system design  
• Expertise in mechanical equipment and electromechanical equipment and related components (e.g., packing and filling lines, pumps, heat exchangers, components such as bearings and pneumatic cylinders) 
• Excellent knowledge of Condition Based Maintenance  
• Excellent data and analytics skills 
• Can analyze large quantities of data QUICKLY to identify correlations and trends  
• Can use small quantities of data (where full year is not available) and make calculated scientific assumptions to identify trends 
• Identify opportunities of improvement by understanding data trends 
• Excellent presentation and soft skills 
• Expert knowledge of MS Excel to be able to build efficiency and energy prediction models  
• Able to present information and trends to the management in an easy to understand and action-oriented way  
• Excellent Bias for action 
• Able to respond to factory and stakeholder needs on time  
• Able to deliver all projects on time in full 
• Understanding and experience in Data Science/Programming will be an advantage 
• Knowledge of Power BI/Tableau etc 
• Food safety knowledge

Qualification and Experience: 

• Minimum bachelor’s degree in mechanical engineering, Electrical Engineering, Electronics Engineering, Mechatronics Engineering or Robotics, or a closely related technical field 
• Intermediate knowledge in MS office/SAP/any CMMS platform 
• Experience in a production environment, particularly in manufacturing or maintenance teams 
• Strong organizational and problem-solving skills 
• Aptitude to learn and display agility 
• Awareness of all the general safety protocols to be followed in a Factory 

What we can offer you

We believe that growth is for everyone, we believe in growing leaders and making space to grow an owner’s mentality and like nature we adapt, we change, and we grow. We believe in connections over hierarchies and (work)levels. We have a 'corporate start-up' approach; we act with speed and agility, and we have the strength and scale of a large corporation. We are building a better world of wellbeing and a better you.