JUSTIN INNASI
Ropes Crossing,Australia
Summary
Maintenance & Engineering Manager with over 25 years of experience in safety-focused, high-performance settings. Expertise in leading cross-functional teams and managing automated industrial assets, resulting in significant improvements in plant availability through reliability practices and advanced CMMS systems. Successfully delivered multimillion-dollar CAPEX projects and optimized asset strategies, achieving over 20% uptime improvements and a 25% reduction in incidents. Proficient in Lean, TPM, and Six Sigma methodologies, with a strong focus on enhancing safety and operational discipline across various industries.
Overview
25
25
years of professional experience
1
1
Certification
Work History
Maintenance Manager
Valmont Coatings
Girraween, Australia
08.2022 - Current
- Directed end-to-end maintenance programs, achieving a 98% scheduled project completion rate through MEX CMMS, while boosting the asset reliability index from 67% to 95% via data-driven preventive schedules.
- Championed quarterly safety initiatives and embedded contractor safety practices, delivering a 28% reduction in incidents and a 35% drop in near-miss events, supported by CMMS analytics and KPI dashboards.
- Oversaw 25+ vendor and service agreements, enforcing SLAs and monitoring KPIs through MEX, which reduced outsourced repair costs by 18% annually.
- Coordinated engineering change control, preventive shutdown planning, and WHS audits, improving regulatory audit scores by 31% and ensuring 100% compliance training participation for 50+ staff.
- Led preventive maintenance and capital upgrade projects across two galvanizing sites, averaging 98% on-time delivery across 20+ initiatives annually.
- Resolved conflicts between internal teams and contractors through structured mediation protocols, cutting project delays by 24% while maintaining service KPIs.
- Valmont Coatings is a leading provider of hot dip galvanizing services across Australia, servicing infrastructure, industrial, and manufacturing clients.
Maintenance Coordinator
ZIP Water
Condell Park, Australia
04.2018 - 07.2022
- Administered Upkeep CMMS and Trello to manage 2,000+ assets, implementing preventive maintenance schedules that boosted equipment uptime by 19% and improved MTBF by 17% across 8 production lines.
- Directed WHS compliance across 5 shifts and coordinated bi-weekly safety audits and training, achieving zero reportable incidents and a 28% increase in audit readiness, exceeding quarterly KPIs.
- Oversaw contractor onboarding and compliance documentation, while leading cross-departmental meetings that accelerated issue resolution by 25% and improved stakeholder engagement.
- Coordinated training for 45 technicians, reducing skills-related maintenance errors by 27% and maintaining 100% training compliance.
- Facilitated cross-functional root cause analysis of failures, achieving a 22% reduction in unplanned downtime, and streamlined budget management to support operational cost control.
- Maintained and upgraded conveyor and packaging systems, reducing breakdown response times by 21% and ensuring consistent achievement of OEE targets.
- ZIP Water is a global leader in instant drinking water systems, operating advanced manufacturing facilities producing automated, refrigerant-based equipment.
Maintenance Toolmaker
Rondo Building Products
, Australia
09.2015 - 04.2018
- Standardised preventive routines for roll-forming machinery, improving uptime by 30% and reducing critical failures by 28%.
- Conducted monthly WHS audits using Riskware, driving a 40% reduction in incident reports within 12 months across all assets.
- Upgraded maintenance protocols for automated equipment and conveyor systems, achieving a 25% decrease in unplanned downtime and a 20% reduction in stoppages.
- Applied advanced mechanical troubleshooting to resolve failures on roll-forming and packaging machines, improving repair turnaround times by 24%.
- Utilised SAP Plant Maintenance to track asset performance, ensuring a 96% on-time completion rate for work orders and sustaining 98% asset availability.
- Mentored junior technicians on SAP PM procedures and troubleshooting methods, accelerating onboarding by 30% and strengthening compliance with safety standards.
- Rondo Building Services is a leading manufacturer of roll-forming products and systems for the construction industry.
Production Technician
Schweppes Australia
Huntingwood, Australia
05.2013 - 08.2014
- Facilitated monthly cross-department technical reviews using SCADA reporting tools, identifying and implementing system upgrades that shortened recovery time after stoppages by 18% and helped sustain 95% monthly uptime.
- Facilitated Team Management initiatives by supervising a 12-member technical crew during three major plant shutdowns per year to enhance cross-shift collaboration and achieve a 10% reduction in monthly downtime incidents.
- Streamlined preventive maintenance schedules across production lines, standardizing workflows and minimizing unplanned equipment failures while supporting consistent high-volume output.
Engineering Technician
ETP Electron Multipliers
, Australia
06.2011 - 05.2013
- Oversaw multi-phase cleanroom and facility modernisation, delivering all commissioning milestones on time and within safety requirements.
- Conducted weekly WHS audits during a 14-month upgrade project, reducing incident rates by 30% and embedding a proactive safety culture.
- Managed statutory compliance programs, scheduling 80+ inspections via MEX CMMS and achieving 100% audit readiness with no non-conformances.
- Deployed MEX CMMS dashboards and digital checklists for 1,200+ weekly shift checks, improving audit scores by 25%.
- Analysed incident trends via CMMS data to implement targeted interventions, achieving a 30% drop in reportable events.
- Coordinated construction schedules and supervised 15+ contractors, ensuring zero delays and strict adherence to safety and conduct protocols.
- Delivered biweekly training sessions for contractors, achieving 100% compliance with the Code of Conduct and reducing conduct-related incidents.
- ETP Electron Multipliers is a high-technology manufacturer specialising in precision vacuum components and electronic detection systems.
Maintenance & Production Technician / Toolmaker
Various
08.2000 - 06.2011
- Delivered predictive and preventive maintenance across high-speed canning and bottling lines, enhancing uptime by 25% through Kaizen and TPM practices.
- Applied precision toolmaking, CAD/CAM, Lean, and Six Sigma methods, achieving a 15% reduction in machining errors year-on-year.
- Supervised crews of 8–30 technicians, boosting productivity by 20% and maintaining 98% adherence to production schedules via structured skills development.
- Executed over 600 PM tasks quarterly, ensuring compliance with WHS and environmental standards while closing skill gaps.
- Strengthened quality assurance processes at major brands, implementing improvements that lowered incident rates by 18%.
- Maintained sheet metal forming, turret presses, and conveyor systems, supporting uninterrupted production flow and regulatory compliance.
- Conducted routine maintenance on production machinery, diagnosing malfunctions to minimize downtime.
- Recorded daily production data for tracking and analysis, facilitating continuous operational improvements.
Education
Master of Engineering Management -
University of Technology Sydney
Sydney01.2015
Graduate Certificate in Engineering - Manufacturing Engineering
University of Technology Sydney
Sydney01.2013
Diploma in Toolmaking -
NTTF Bangalore
India09-2001
Skills
- Team leadership and staff management
- Equipment maintenance and inspection
- CMMS optimization and management
- Safety compliance and protocols
- Contract negotiation and management
- Predictive and preventive maintenance
- Vendor and contractor management
- Regulatory audits and compliance
- Cost reduction strategies
- Asset reliability improvement
- Conflict resolution and problem solving
- Communication skills and training development
- Resource allocation and budget administration
- Facilities maintenance and emergency response
- Reporting, documenting, and incident investigation
- Process optimization and adaptability
- Strategic planning and change leadership
- Stakeholder engagement and workforce development
- Reliability engineering and shutdown planning
- Capital project delivery and asset lifecycle management
Certification
- CSAM - Certified Senior Practitioner in Asset Management, 2023
- TMIEAust – Technologist Member, Engineers Australia, 2025
Accomplishments
- Improved asset availability by 20%+ through predictive maintenance and CMMS integration.
- Reduced safety incidents by 28% and near misses by 35% through proactive safety leadership.
- Delivered multimillion-dollar CAPEX projects on-time, in full, and within budget, including site upgrades and new installations.
- Successfully led and developed teams of 100+ technicians and contractors, building high-performance cultures.
- Cut maintenance backlog by 60% through preventive and reliability-centered strategies.
- Spearheaded Lean initiatives that delivered $600K+ annual savings through waste reduction and process optimization.
References
To be supplied if requested
Key Areas Of Expertise
- Leadership & People Development
- Reliability & Preventive Maintenance
- Safety & Compliance
- Automation & Engineering Systems
- Continuous Improvement
- Stakeholder & Vendor Management
Timeline
Maintenance Manager
Valmont Coatings
08.2022 - Current
Maintenance Coordinator
ZIP Water
04.2018 - 07.2022
Maintenance Toolmaker
Rondo Building Products
09.2015 - 04.2018
Production Technician
Schweppes Australia
05.2013 - 08.2014
Engineering Technician
ETP Electron Multipliers
06.2011 - 05.2013
Maintenance & Production Technician / Toolmaker
Various
08.2000 - 06.2011
Master of Engineering Management -
University of Technology Sydney
Graduate Certificate in Engineering - Manufacturing Engineering
University of Technology Sydney
Diploma in Toolmaking -
NTTF Bangalore