Maintenance Manager

Purpose:

Ensure the safe, reliable, and efficient operation of all plant equipment, buildings, and installations through proactive maintenance management, leadership of PLC and automation systems, team supervision, and continuous improvement.

Direct Reports:

Union Maintenance Technicians, PLC Technician.

Key Responsibilities:

Leadership & Team Management

1. Supervise and lead all maintenance personnel, including PLC Technician and subcontractors.
2. Recruit, train, and develop the maintenance team to ensure capability for projected workloads and projects.
3. Foster a problem-solving and continuous improvement culture, building strong and positive working relationships.
4. Ensure fulfillment of Union Agreement requirements.

Maintenance Strategy & Execution

1. Develops technical capabilities within the maintenance team and supports continuous improvement toward operational excellence and increased automation
2. Develop, implement, and execute preventive maintenance plans for equipment, buildings, and installations.
3. Oversee repairs, installations, and equipment rebuilds, including scheduling, cost evaluation, and resource allocation.
4. Drives automation initiatives through PLC programming, troubleshooting, and integration of control systems to improve process efficiency and data accuracy.
5. Lead and support PLC Technician to ensure optimal operation of control systems and automated equipment.
6. Lead CAPEX projects and initiatives related to automation, process improvements, and system upgrades.
7. Conduct regular inspections and handle maintenance emergencies.
8. Implement proactive maintenance strategies and monitor KPIs (MTBF, MTTF, PM execution, OEE).

Compliance, Safety & Standardization

1. Ensure strict adherence to OSHA and Vesuvius Group standards.
2. Standardize work methods via procedures, work instructions, and technical documentation (drawings, registers, specifications).
3. Manage maintenance SCARs and ensure regulatory compliance in all maintenance activities.
4. Implement and maintain 5S in all subordinate areas.

Resources & Budget Management

1. Manage maintenance budgets, expenses, and financial KPIs (cost reduction programs, adherence to budget).
2. Ensure availability of tools, equipment, and spare parts; manage procurement, inventory, and vendor negotiations.

Continuous Improvement & Reporting

1. Drive initiatives to improve productivity, reliability, and cost efficiency.
2. Document daily progress, maintain maintenance logs, and report performance metrics.
3. Identify opportunities for automation, reliability improvements, and process optimization.
4. Perform other duties as assigned.

Key Result Areas (KRAs):

1. Maintenance Reliability & Execution: Timely and effective execution of the Planned Preventive Maintenance (PPM) program, ensuring minimal unplanned downtime.
2. Safety Performance: Improvement in safety metrics, including LTFR, MTIFR, and reduction of incidents and dangerous occurrences.
3. Operational Performance: Achievement of maintenance KPIs (MTBF, MTTF, PM plan execution, OEE) and financial KPIs (adherence to budget, cost reduction programs).
4. Team Development & Training: Development and implementation of cross-training programs and technical upskilling for Maintenance Technicians, including PLC and automation competencies.
5. Communication & Process Compliance: Establishing clear communication channels across departments to ensure all maintenance processes, procedures, and workflows are followed.
6. Safety & Culture Leadership: Support and drive group safety culture initiatives and continuous improvement toward exceeding company targets.
7. Compliance & Values: Adherence to all company values, policies, procedures, and Union Agreement requirements.

Education & Qualifications:

• Bachelor’s degree in Mechanical, Electrical, Industrial, or Manufacturing Engineering, or a closely related field.
• Master’s degree in Engineering, Industrial Management, or Reliability/Asset Management is a plus.
• Certifications preferred:
  • Certified Maintenance & Reliability Professional (CMRP)
  • PLC or Automation certifications relevant to the industry
• Strong knowledge of maintenance strategies, industrial automation, and PLC systems.
• Experience with budgeting, CAPEX planning, and resource management.
• Familiarity with safety regulations, OSHA, and Quality Management Systems.
• Experience working in a union environment is preferred.
• Strong leadership, problem-solving, and project management skills.

 Skills & Behaviors:

• Strong leadership and ability to develop and manage teams
• Excellent problem-solving and decision-making skills
• Effective time management and ability to prioritize under pressure
• High adaptability in a dynamic, fast-paced environment