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Maintenance Head
Company: ESSA
Industry: Energy and Chemicals
Role overview
ESSA is seeking an experienced Maintenance Head to lead maintenance strategy and execution across its energy and chemical operations. The role is accountable for the safe, reliable and cost-effective performance of plant equipment, utilities and facilities. The successful candidate will build a proactive, data-led maintenance culture, strengthen asset integrity, and work closely with operations, engineering, HSE and supply chain teams to support production and business objectives.
Key responsibilities
Develop and implement maintenance strategies, policies and annual plans aligned with production requirements, asset risk and business priorities.
Lead preventive, predictive, corrective and breakdown maintenance for process equipment, rotating and static machinery, electrical systems, instrumentation, utilities and facilities.
Improve equipment availability, reliability and maintainability by applying root-cause analysis, failure analysis and continuous-improvement methods.
Oversee maintenance planning and scheduling, work prioritization, backlog control, shutdowns, turnarounds and major repair activities.
Ensure work is performed in accordance with applicable safety, environmental, quality and asset-integrity requirements, as well as company procedures and relevant regulations.
Promote safe systems of work, including risk assessments, permit-to-work controls, isolation and lockout/tagout practices, and contractor safety management.
Manage maintenance budgets, operating expenditure, capital requests, lifecycle costs, spare-parts strategy and inventory levels.
Lead, develop and retain maintenance personnel; define responsibilities, set performance expectations and build technical capability through coaching and training.
Select, manage and evaluate contractors and service providers, ensuring that work meets agreed standards for safety, quality, cost and schedule.
Establish and monitor key performance indicators such as equipment availability, maintenance cost, schedule compliance, repeat failures and backlog health.
Ensure accurate maintenance records and effective use of the computerized maintenance management system (CMMS), including equipment data, job plans and work history.
Work with operations and engineering teams to coordinate maintenance windows, manage plant changes and support commissioning or modification projects.
Prepare maintenance reports, forecasts and improvement proposals for senior management, and communicate operational risks and resource needs clearly.
Key working relationships
The Maintenance Head works closely with plant and operations leaders, engineering, HSE, quality, procurement, finance, project teams, contractors and equipment suppliers.
Success in the role
Success will be reflected in improved asset reliability and availability, fewer repeat failures and unplanned outages, effective cost control, strong audit and safety performance, and a capable, accountable maintenance team.
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- Essential requirements
- Bachelor’s degree in Mechanical, Electrical, Instrumentation, Chemical or another relevant engineering discipline; an equivalent combination of education and experience may be considered.
- Substantial progressive experience in industrial maintenance, including leadership responsibility in an energy, chemical, petrochemical, refining, process-manufacturing or similarly complex operating environment.
- Strong knowledge of maintenance and reliability practices for process plants, including preventive and predictive maintenance, equipment troubleshooting, asset integrity and failure analysis.
- Demonstrated experience planning and executing major shutdowns, turnarounds, overhauls or large-scale maintenance projects.
- Working knowledge of relevant occupational safety, environmental and engineering requirements, and the ability to embed safe work practices in daily maintenance activities.
- Experience managing maintenance budgets, contractors, spare parts, procurement interfaces and competing operational priorities.
- Practical experience using a CMMS and maintenance performance data to plan work, track asset history and improve results.
- Proven ability to lead multidisciplinary teams, develop technical talent and build constructive relationships across departments.
- Strong analytical, problem-solving and decision-making skills, including the ability to assess equipment risk and prioritize work accordingly.
- Clear written and verbal communication skills, with the ability to prepare reports and present recommendations to senior stakeholders.
- Preferred qualifications
- Professional engineering registration, chartered status or a relevant maintenance or reliability certification.
- Formal training or certification in reliability engineering, asset management, condition monitoring, project management or maintenance planning.
- Experience with recognized asset-management and reliability standards or methodologies, such as ISO 55000 principles, risk-based maintenance, RCM or FMEA.
- Experience supporting capital projects, equipment commissioning, plant modifications or maintenance digitalization initiatives.
- Personal attributes
- Strong commitment to safety, integrity, environmental responsibility and regulatory compliance.
- Calm and decisive under pressure, particularly during equipment failures and operational disruptions.
- Organized, accountable and improvement-oriented, with a focus on sustainable results rather than short-term fixes.
- Collaborative and adaptable, able to work effectively with people at all levels of the organization.