Maintenance Manager (manufacturing)

The Maintenance Manager reports to the Plant manager and is a member of the plant leadership team.  Manages the Operations Maintenance Leader, and three E&I technicians and 6 maintenance mechanics. 

Job dimensions

The maintenance manager has direct responsibility for maintenance and service of the plant.  This includes management of the annual maintenance and facilities budget of ~$1.5M.  Drives excellence in maintenance work processes and part management to improve plant cost and productivity.

Key Activities and responsibilities

[10%] Maintain HSEQ (health, safety, environmental, quality) compliance as top priority.

• Follow all HSEQ policies and practices. This includes compliance with environmental regulations and permits, quality systems, and safe work practices (RTM, LOTOTO, CSE, Hot Work, Etc.).

• Demonstrate commitment to all HSEQ matters through individual actions that include CARE observations, SWP audits, RTS/LOTOTO audits, review of higher risk maintenance plans (Critical lift, high energy hot work, CSE, multiple crafts in close proximity, etc.)

• Lead the maintenance department in safe work practices in accordance with OSHA, EPA and company EHS requirements.

• Ensure timely response to ATLAS First Report Events that involve repair work.

• Manages contractor safety program including contractor qualification through Avetta.

[40%] Plant Maintenance & Budget

• Ensure daily maintenance activities are prioritized in alignment with the needs of Manufacturing and Planning departments.

• Coordinate facilities management both internal and via 3rd party contractors.

• Develop and manage maintenance and facilities budget.  Track committed cost to achieve spend to budget and provide spend forecast.

• Manage the maintenance work order system, equipment register and metric reporting.

• Provide support and guidance for the maintenance team including work prioritization across all shifts.

• Continuously drive operational efficiency improvements at the Middleton plant through improvements in maintenance processes thus increasing equipment uptime and efficiency. 

• Develop and achieve maintenance team improvement goals and objectives in alignment with both Business and Plant Key Performance Indicators (KPIs).

[15%] Continuous Improvement

• Continuously drive improvements in the operational efficiency and reliability of the plant through improvements in maintenance processes and equipment downtime and efficiency.  Use lean tools, including OEE, to identify priorities.

• Identify and execute opportunities to drive fixed cost improvement through 3rd party vendor and service providers and work process efficiency improvements.

• Use equipment failure data to revise the preventative maintenance program to improve asset reliability and safety while optimizing uptime and reducing cost.

• Identify and execute small CAPEX projects to improve and maintain equipment capabilities.

• Lead maintenance natural work team in SMART operational excellence processes.  Identify key KPIs and track at Tier meetings.  Ensure effective problem-solving culture within maintenance team.

[10%] Maintenance Team Management

• Maintain knowledge of work scope for planned maintenance outages (RTO outages, unit outages …)

• Maintain and coordinate maintenance work schedule, attendance, and payroll.

• Coach, train and develop members of the maintenance department to achieve desired performance.

[<5%] Perform other duties as assigned.

Position has limited travel (<5%), predominately for training and development opportunities.

Required Education/Qualifications /Work experience

• Minimum of a B.S. degree in Chemical or Mechanical Engineering or commensurate experience

• Minimum 10 years of experience in a PSM-covered chemical plant setting and 3-5 years of leadership experience.

• Strong leadership, communication, organizational and team-building skills

• Demonstrated computer skills (MS Office, AutoCAD and CMMS, ideally EAM)

• PLC skills preferable, including troubleshooting and configuration

• Strong work ethic and the ability to work in cross-functional teams to deliver concrete results quickly.

• Demonstrated Competencies (Describe behaviors necessary for role)

• Ability to work cooperatively with others.

• Ability to communicate effectively with all levels of the organization.

• Demonstrates initiative, personal drive and accountability.

• Strong organizational skills.