Head Of Maintenance

Dangote Packaging Limited

Job Purpose:

The Head of Maintenance is responsible for leading and overseeing the entire maintenance function of DPL plant. This includes preventive, predictive, and breakdown maintenance of all machinery involved in tape extrusion, weaving, circular looms, lamination, printing, conversion, and utilities. The role ensures maximum machine uptime, efficient asset management, cost control, safety compliance, and continuous improvement across the plant.

Duties & Responsibilities:

1. Maintenance Strategy & Planning

• Develop and implement comprehensive preventive and predictive maintenance schedules for all production and utility equipment.
• Plan and supervise shutdown maintenance activities.
• Establish maintenance KPIs such as MTTR, MTBF, breakdown frequency, energy efficiency, and uptime.

2. Equipment & Machinery Maintenance

• Lead maintenance activities for:
• Tape extrusion lines
• Circular looms (4/6 shuttle, 8/10/12 shuttle)
• Lamination/coating plants
• Flexographic & rotogravure printing machines
• Bag conversion & stitching machines
• Air compressors, chillers, boilers, generators
• Material handling systems
• Improve machine life, reliability, and performance through engineering interventions.

3. Team Leadership

• Manage and mentor a team of maintenance engineers, supervisors, technicians, and electricians.
• Ensure skill development through regular training programs.
• Assign tasks, monitor performance, and ensure adherence to procedures.

4. Breakdown & Troubleshooting

• Ensure quick diagnosis and resolution of machine breakdowns to minimize downtime.
• Lead root cause analysis (RCA) for repetitive issues and implement permanent corrective actions.
• Maintain a 24/7 readiness plan for critical equipment.

5. Inventory & Spare Parts Management

• Optimize spare parts inventory and maintain critical stock levels.
• Coordinate with procurement for cost-effective sourcing of spares and consumables.
• Reduce maintenance cost through standardization and vendor development.

6. Safety, Compliance & Documentation

• Ensure compliance with ISO, safety, audit, and legal requirements.
• Maintain proper documentation: machine history cards, maintenance logs, calibration records, Lubrication charts.
• Implement safety practices such as LOTO, PPE usage, and hazard-risk assessments.

7. Project Management & Improvements

• Lead installation, commissioning, and upgrades of new machinery.
• Drive continuous improvement and energy optimization initiatives.
• Develop automation and digitalization strategies wherever feasible.

Job Requirement:

Educational Qualification & Experience

• Education: Minimum B. Eng. or HND in Mechanical Engineering or related disciplines
• Experience: Minimum 10 - 20 years in maintenance, preferably in PP woven sacks/plastics/packaging manufacturing
• Added Advantage: Experience in managing large manufacturing facilities and multi-disciplinary teams 
• Professional Membership & Certifications: COREN. Added advantages: NSE, PMP

Competencies:

• Strong knowledge of PP woven sac machinery & processes
• Expertise in electrical, mechanical, and instrumentation systems
• Strong troubleshooting and analytical skills
• Leadership and team-building abilities
• Knowledge of hydraulics, pneumatics, VFDs, PLCs
• Budgeting, planning, and vendor management
• Strong documentation and reporting skills
• Commitment to workplace safety