Req ID | Darlaston, United Kingdom, ZF Lemforder UK Limited
About the Role
As a key member of the Plant Leadership Team, the Engineering & Maintenance Manager is responsible for delivering world-class equipment availability, process capability, and plant infrastructure. This role combines strategic engineering leadership with hands-on maintenance and facilities management, ensuring safe, compliant, and efficient manufacturing operations. It spans process engineering, facilities and site services, environmental health & safety systems, automation and digital manufacturing integration, and the deployment of continuous improvement initiatives aligned with ZF Production System (ZFPS) standards.
What you can look forward to as Engineering and Maintenance Manager:
1. Leadership & Team Management: Lead, motivate, and develop a multi-disciplinary engineering and maintenance team across multiple shifts by setting clear objectives, managing performance, and building capabilities to meet current and future plant requirements, while embedding a culture of safety, quality, and continuous improvement in alignment with ZF’s operational excellence strategy
2. Engineering Management: Lead process and test engineering for current production and new product introduction, drive automation initiatives including robot and AGV implementation, oversee lean manufacturing line design and optimisation, ensure accurate documentation (PFMEAs, Control Plans, Standard Work), manage CAPEX projects from justification to commissioning, and support zero-defect performance through rapid root cause problem-solving
3. Maintenance & Facilities Management: Own and implement preventive, predictive, and autonomous maintenance systems to improve OEE, MTBF, and MTTR; manage site utilities, infrastructure, and statutory compliance; oversee facility upgrades and equipment installations; control maintenance budgets and inventory; and continuously improve the CMMS for data-driven decision-making
4. Operational Excellence & ZFPS Deployment: Ensure full compliance with ZF Production System standards by embedding lean tools such as 5S, TPM, SMED, standardised work, and visual management; lead continuous improvement initiatives to reduce downtime, scrap, and cost while improving throughput, yield, and labour efficiency; and leverage MES/Digital Manufacturing Platform data to drive targeted engineering and maintenance Actions
5. Health, Safety, Environment & Compliance: Support the EHS coordinator to ensure compliance with ISO standards (,,, ) and statutory regulations; manage contractor control, permits to work, and site safety systems; promote energy reduction and carbon neutrality initiatives; and enforce a zero-accident culture through proactive hazard identification, risk assessments, and safety Audits
6. Customer, Supplier & Stakeholder Engagement: Support customer audits and visits by presenting engineering and maintenance improvements; collaborate with suppliers and OEMs on equipment upgrades, modifications, and issue resolution; and partner with cross-functional teams to ensure seamless support for production operations
Your Profil as Engineering and Maintenance Manager:
7. Degree in Engineering (Mechanical/Electrical/Manufacturing) or equivalent significant experience; HNC/HND minimum in relevant discipline; NEBOSH or equivalent safety qualification desirable.
8. Proven track record in automotive/manufacturing engineering and maintenance leadership.
9. Strong background in both mechanical and electrical disciplines.
10. Experience in CAPEX project delivery, TPM implementation, and lean manufacturing.
11. Knowledge of IATF, VDA 6.3, ISO, ISO,,, and customer-specific requirements (e.g., JLR, Ford and BMW).
12. Demonstrates strategic thinking with a hands-on approach, strong leadership, and effective communication across all levels
13. Excels in problem-solving, analysis, and decision-making, with outstanding organizational and time management skills to handle multiple priorities.
14. Possesses solid financial acumen for budget and ROI analysis, and is IT literate with experience in CMMS and manufacturing systems (MES/DMP)