Purpose of the Role

The Maintenance and Programming Manager will be responsible for leading the maintenance and automation team for the client’s Plants in ensuring optimal equipment performance, minimal downtime, and seamless integration of control systemsparticularly in a high-volume automotive manufacturing environment – are met. This role demands advanced knowledge of Siemens S7 PLC programming, hands-on experience with press tooling, mechanical press shop experience, and the ability to lead maintenance strategies across production shifts.

Minimum Requirements

• National Diploma or BTech in Electrical Engineering (Light Current/Electronics), Mechatronics, or equivalent qualification.
• Minimum 10 years of experience in maintenance/automation in the automotive manufacturing sector.
• At least 5 years experience in managing multidisciplinary maintenance teams.
• In-depth knowledge and experience in:
  o Siemens S7 PLC programming using TIA Portal
  o Step 7 Siemens PLCs (including transition to TIA Portal)
  o Simotion Scout (advantageous)
  o Press tooling (maintenance, repair)
  o Pneumatic & hydraulic systems (FESTO/SMC, HYDAC/Besko)
• o Strong mechanical minded aptitude (Conveyors, rollers, pulleys & gears)
• o Industrial robotics (advantageous)
• o Electrical fault finding and wiring

• Regular travelling between client’s plants required to provide support and management; this will be especially applicable during critical breakdowns or shutdowns.
• Strong experience with preventative maintenance systems, OEE improvement, TPM methodologies, and spare parts management.

Key Responsibilities

• Lead the maintenance and automation department to ensure 24/7 equipment availability for production. This includes the management of maintenance staff (often operating in shifts) as well where required providing hands on assistance
• Oversee preventative and reactive maintenance of production assets, with a strong focus on press tools and automated production lines.
• Programming, fault finding, and optimization of Siemens S7 PLCs within TIA Portal.
• Provide hands-on support during production breakdowns, ensuring rapid root cause analysis and sustainable resolution.
• Liaise with Production staff as to maintenance requirements and implement corrective actions / plans to ensure downtime is minimised.
• Implement structured root cause analysis (RCA) methodologies to prevent recurring equipment failures and drive continuous improvement.
• Manage software backups and documentation of all PLC-controlled systems.
• Supervise installation, modification, and commissioning of new automation systems and equipment.
  Interpret and work with hydraulic, pneumatic, and electrical schematics.
• Manage and maintain FESTO/SMC pneumatic valve systems.
• Lead and develop a team of artisans and technicians, including shift-based personnel.
• Compile and report key maintenance KPIs (downtime analysis, MTTR, MTBF, RCA effectiveness, etc.).
• Plan and oversee shutdown maintenance activities (for VM plants). Where and when required, you will need to provide direct and in person oversight.
• Develop and oversee a critical spares management program to minimize downtime risks, ensuring optimal stock levels, availability of essential components and safeguarding of such.
• Manage, compile, and control the budget for the maintenance department, ensuring cost-effective operations and strategic allocation of resources.
• Collaborate with procurement and suppliers to reduce lead times, manage obsolescence, and optimize spare parts costs.
• Ensure compliance with safety, environmental, and quality standards.

Competencies

• Strong leadership and team management skills
• Excellent problem-solving and analytical skills
• Budgeting and cost management expertise
• Strategic and forward-thinking approach to maintenance management
• Able to work under pressure and make quick, informed decisions
• Hands-on approach working closely with production and toolroom to ensure uptime is maximized and downtime is structured and productive on the shop floor
• Comfortable working on mechanical presses and understanding the tooling/production interface.
• Excellent communication and reporting skills
• Adaptability and continuous improvement mindset
• Practical, solutions-focused leader who thrives under pressure and can work independently.

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