Maintenance Manager

To lead the maintenance function at Tyseley, ensuring the plant and equipment are maintained safely, reliably and cost-effectively. The Maintenance Manager develops the team, owns maintenance planning and delivery, and works with the Operations Manager to improve availability and reduce repeat failures. The role combines effective breakdown response with preventative maintenance, statutory inspection planning and long-term asset care, with clear control of contractors, expenditure and work quality.

The key metrics are

• Safety, Statutory Inspection and Corrective Action Completion
• Plant Availability, Maintenance Downtime and Repeat Failures
• Maintenance Schedule Compliance and Overdue Critical Work
• Outage Delivery and Maintenance Budget Performance
• Team Competence, Work Quality and Housekeeping

Roles & Responsibilities

• Lead, coach and manage the Maintenance Team, setting clear responsibilities, reviewing performance and maintaining a competency and development plan for each team member.
• Own the maintenance programme and computerised maintenance management system(CMMS), maintaining accurate asset records, job plans, equipment histories and preventative maintenance schedules.
• Agree weekly work priorities with Operations, assess defects by risk and equipment criticality, and ensure labour, parts, permits and access are available before work starts.
• Control the maintenance backlog. Escalate overdue critical work and ensure any deferral is risk assessed, approved through the site process and given a revised completion date.
• Maintain awareness of plant conditions and coordinate breakdown response, deploying competent resources, communicating restoration forecasts and agreeing safe return to service with Operations.
• Investigate significant and recurring failures, identify underlying causes and implement corrective actions. Verify their effectiveness and update maintenance tasks or operating guidance where necessary.
• Plan and deliver outages, controlling scope, schedules, resources, spares, contractor interfaces and costs; verify work completion and restart readiness, and capture lessons learned.
• Maintain the statutory inspection programme within the maintenance remit, arranging competent examinations, retaining records and closing defects, including requirements relating to PSSR, LOLER and COSHH.
• Ensure maintenance work follows approved risk assessments, method statements, Permit to Work and isolation arrangements. Exercise permit and electrical duties only within formal site authorisation.
• Select and manage competent contractors against safety, capability, quality, cost and availability; confirm scope, supervise performance and verify completed work before recommending payment.
• Manage maintenance expenditure within agreed budgets and approval limits, obtain competitive quotations where appropriate, forecast commitments and explain variances to the Plant Manager.
• Maintain critical spares and consumables, considering equipment criticality, stock accuracy and supplier lead times; identify obsolescence risks and recommend lifecycle investment priorities.
• Develop reliability and efficiency improvements with Operations, subject equipment modifications to the site change-control process and maintain current drawings and technical documentation.
• Provide technical support across the site and participate in the agreed on-call rota, ensuring effective handover of outstanding defects, restrictions and planned work.

Key Accountabilities

• Maintain safe working standards under the Health and Safety at Work etc. Act 1974, TOL rules and company policies; ensure staff and contractors follow applicable procedures.
• Deliver planned preventative and condition-based maintenance (CBM) to CMMS schedules, recording findings and ensuring defects receive an owner, priority and completion date.
• Deliver the maintenance contribution to the plant availability target of 80% or above, investigating maintenance-related losses and progressing agreed recovery actions.
• Deliver agreed work and outage milestones to the required quality and budget; escalate risks to safety, compliance, cost or completion before commitments are missed.
• Submit the monthly departmental report by close of business on the Friday of the first week following month-end, covering KPIs, downtime, backlog, statutory inspections, expenditure and improvement actions.
• Maintain inspection and maintenance records that demonstrate completed work, and ensure workshops, stores and work areas remain clean, orderly and safe.

Systems and Processes

• Fuel reception, handling and delivery conveyors.
• Gasification and combustion systems, including associated fans and drives.
• Boiler, steam, feedwater, condensate and drainage systems.
• Steam turbine, generator and associated cooling and auxiliary systems.
• Flue gas abatement, reagent delivery and ash handling systems.
• Water treatment plant and associated pumps, valves and pipework.
• Electrical distribution, motors, instrumentation and control equipment, within the team's competence and site authorisations.

Experience/Qualifications/Skills

• Relevant engineering qualification, recognised apprenticeship or equivalent demonstrable technical experience.
• Proven maintenance management or supervisory experience in an industrial process environment; power generation, biomass or energy-from-waste experience is desirable.
• Strong leadership, coaching and performance management skills, with the ability to develop a multi-disciplinary team.
• Sound mechanical and electrical maintenance knowledge, with practical fault-finding, root cause investigation and preventative maintenance experience.
• Experience using a CMMS to plan work, control backlog, maintain records and report performance; experience of outage planning and contractor management.
• Understanding of safe systems of work, isolations, statutory inspection arrangements and the limits of personal competence and authorisation.
• Commercial awareness, including budget control, procurement and critical spares management, supported by clear reporting and communication skills.
• A proactive, organised approach and flexibility to participate in the on-call rota and support planned outages.