Basic Summary:
The Head of Maintenance is responsible for leading all maintenance activities across the site to ensure equipment reliability, regulatory compliance, and uninterrupted operations. The role oversees preventive, predictive, and corrective maintenance programmes, machine control systems, utilities, and engineering support to production. This role ensures GMP compliance and drives maintenance and automation excellence in alignment with the Head of Engineering.
Location: Onsite at our facility in Loughrea.
As our Head of Maintenance, your key responsibilities will be as follows:
Maintenance Leadership Strategy:
* Lead the maintenance organisation across mechanical, electrical, instrumentation, machine control systems, and utilities.
* Develop and execute a maintenance strategy aligned to site reliability, OEE, and downtime-reduction targets.
* Implement world-class maintenance practices (TPM Total productive maintenance, RCM Reliability centred maintenance, reliability engineering).
GMP Regulatory Compliance
* Ensure maintenance activities comply with HPRA/FDA/EU GMP requirements.
* Maintain validated state of equipment, utilities, and automated systems.
* Own maintenance SOPs, calibration requirements, engineering logs, and documentation.
* Ensure audit readiness and support regulatory inspections.
Preventive, Predictive Corrective Maintenance
* Manage PM and PdM programmes including scheduling, execution, and documentation.
* Implement predictive technologies—vibration, thermography, oil analysis, condition monitoring.
* Lead troubleshooting and RCA for equipment failures.
Machine Control Systems
* Own maintenance responsibility for all machine control systems including PLCs, SCADA, HMIs, vision systems, servo controls, recipe systems, and automated safety systems.
* Ensure all automation systems and control panels are compliant, documented, and maintained in validated state.
* Lead fault-finding on automated equipment and support troubleshooting of complex controls issues.
* Partner with Automation/IT/Process Engineering on upgrades, cybersecurity compliance, and digital validation.
* Manage software backups, version control, and change control for control system modifications.
* Implement preventative maintenance routines for control systems.
* Support integration of new equipment, FAT/SAT, commissioning and qualification of automated systems.
Reliability Engineering
* Lead asset criticality ranking, maintenance strategies, and reliability improvement plans.
* Perform FMEA/FMECA investigations and drive CAPA effectiveness.
* Partner with Engineering Director on asset lifecycle planning and replacement CAPEX.
Utilities Facilities Support
* Oversee reliable operation of critical utilities (HVAC, PW/RO, compressed air, chillers, boilers, cleanroom systems).
* Ensure utilities operate within specification to support batch release.
CMMS Work Management
* Implement own the CMMS Computerised maintenance management system including work order flow, backlog control, and job planning.
* Ensure accurate data integrity, asset hierarchy, and maintenance history capture.
* Drive KPI reporting: PM compliance, MTBF Mean time between failures, MTTR Mean time to repair, critical downtime.
People Management Development
* Lead and develop maintenance teams across trades and automation disciplines.
* Build technical capability via targeted training and cross-skilling.
* Ensure contractor control, permits-to-work, and safe systems of work.
Health, Safety Environmental
* Ensure safe execution of all maintenance work (LOTO, risk assessments, machinery safety).
* Support site energy, environmental, and sustainability initiatives.
Budget Cost Control
* Manage maintenance budgets, service contracts, and spare parts.
* Implement cost saving and reliability-improvement initiatives.
Education and Experience:
Essential:
* Degree or trade qualification in Mechanical, Electrical, Mechatronic, Automation, or related engineering discipline.
* 7+ years maintenance leadership in a GMP-regulated environment.
* Strong experience with PLC/SCADA/HMI-controlled equipment.
* Demonstrated experience implementing PM, PdM, and reliability programmes.
* Strong understanding of GMP, validation, and regulatory requirements.
Desirable:
* Experience with digital maintenance tools, CMMS optimisation, and Industry 4.0 systems.
* Experience with vision systems, servo drives, robotic systems, or high-speed packaging lines.
* Lean, TPM, or Six Sigma certification
Skills and Competencies:
* Strong leadership and people skills.
* Technical problem-solver with a hands-on mindset.
* Excellent communication across Operations, Engineering, Quality, and EHS.
* High level of organisation and time management.
* Data-driven decision-maker with strong reliability mindset.
Applicants from diverse backgrounds, including those returning after a career break or with transferable skills from non-traditional career paths, are encouraged to apply. We value varied experiences and are committed to fostering an inclusive environment that supports individuals with disabilities.