The Senior Engineer - Plant & Machinery is responsible for ensuring the reliable operation, maintenance, and continuous improvement of plant machinery and equipment. The role requires strong technical expertise in mechanical systems, project management capabilities, and leadership skills to drive operational efficiency, equipment reliability, safety compliance, and team performance.
Key Responsibilities
Maintenance & Equipment Reliability
Oversee the maintenance, repair, and troubleshooting of all plant machinery and mechanical equipment.
Ensure optimal performance, reliability, and availability of plant assets to support uninterrupted operations.
Develop, implement, and continuously improve preventive and predictive maintenance programs for critical equipment.
Conduct root cause analysis (RCA) for equipment failures and recurring issues, and implement effective corrective and preventive actions.
Monitor equipment performance and recommend upgrades or modifications to improve reliability and efficiency.
Project Management
Lead machinery installation, commissioning, upgrade, replacement, and modernization projects.
Develop project plans, schedules, budgets, and resource requirements to ensure successful project delivery.
Coordinate with Operations, Engineering, Procurement, and external vendors to ensure smooth project execution.
Ensure projects are completed safely, on time, within budget, and in accordance with technical specifications.
Continuous Improvement & Operational Excellence
Identify opportunities to improve equipment performance, reduce downtime, and optimize maintenance costs.
Drive continuous improvement initiatives focused on productivity, asset utilization, and operational efficiency.
Implement best practices in reliability engineering, maintenance management, and asset lifecycle management.
Analyze maintenance data and performance trends to support informed decision-making and process improvements.
Health, Safety & Compliance
Ensure compliance with all applicable safety regulations, company policies, and maintenance procedures.
Verify that plant machinery operates within established safety, environmental, and operational standards.
Lead machinery-related risk assessments, audits, inspections, and safety reviews.
Promote a strong safety culture and ensure adherence to safe work practices across maintenance activities.
Team Leadership & Development
Lead, mentor, and develop engineers, supervisors, and technicians to build a high-performing maintenance team.
Provide technical guidance and support to resolve complex equipment issues.
Foster a collaborative work environment that encourages innovation, knowledge sharing, and continuous learning.
Work closely with production and operations teams to align equipment capabilities with production requirements and business objectives.
Documentation & Reporting
Maintain accurate records of maintenance activities, equipment repairs, service histories, and asset performance.
Prepare and present regular reports on equipment reliability, downtime, maintenance costs, and key performance indicators (KPIs).
Ensure proper documentation of machinery manuals, technical specifications, maintenance procedures, and upgrade records.
Utilize CMMS and other maintenance management systems to track and optimize maintenance activities.
Qualifications & Experience
Bachelor's Degree in Mechanical Engineering or a related discipline.
Minimum 8-12 years of experience in plant maintenance, machinery engineering, or industrial operations.
Proven experience in managing maintenance operations, equipment reliability, and capital projects within industrial or manufacturing environments.
Strong knowledge of mechanical systems, rotating equipment, pumps, compressors, conveyors, and other plant machinery.
Experience with preventive, predictive, and reliability-centered maintenance practices.
Familiarity with CMMS, maintenance planning tools, and asset management systems.