Maintenance Manager

Position Summary

The Maintenance Manager is responsible for the safe, reliable, and compliant operation of all mechanical, electrical, and process utility systems within an electroplating manufacturing environment. This role leads a team of maintenance technicians and coordinates all planned and reactive maintenance activities across the plating lines, rectification systems, chemical process equipment, ventilation infrastructure, and facility utilities. The Maintenance Manager drives continuous improvement through data-driven maintenance methodologies, rigorous spare parts management, and disciplined work order execution.

Key Responsibilities:Rectifier & Electrical Systems:

• Oversee maintenance, calibration, and periodic overhaul of DC rectifiers, thyristor banks, and associated bus bar assemblies used in electroplating processes.
• Monitor rectifier output parameters (voltage, amperage, ripple) to ensure process bath integrity and plating quality consistency.
• Partner with process engineering to diagnose electrical faults and recommend rectifier upgrades or replacements aligned with production requirements.
• Ensure lockout/tagout (LOTO) procedures for all high-voltage systems are enforced and maintained in current documentation.
• Coordinate third-party electrical inspections and maintain compliance with applicable OSHA electrical standards.

Plumbing & Chemical Process Systems:

• Manage maintenance and integrity of all process plumbing including chemical transfer lines, rinse water systems, drag-out recovery systems, and wastewater pre-treatment infrastructure.
• Oversee pump, valve, and piping inspections for chemical-resistant materials (PVC, CPVC, polypropylene) used across acid, alkaline, and cyanide bath circuits.
• Coordinate preventive maintenance on filter systems, heat exchangers, agitation systems, and chemical dosing equipment.
• Ensure proper containment and secondary containment systems are functional and compliant with EPA and state environmental regulations.
• Work closely with the EHS team on spill prevention, containment plan (SPCC) compliance, and chemical handling procedures.

Ventilation & Air Handling Systems:

• Direct preventive and corrective maintenance of local exhaust ventilation (LEV) systems, fume hoods, push-pull ventilation over open plating tanks, and facility makeup air units (MAUs).
• Ensure ventilation systems meet OSHA air quality standards.
• Schedule periodic airflow testing, static pressure balancing, and ductwork inspections to maintain hood face velocities within specification.
• Manage filter media change-outs (mist eliminators) and maintain records for regulatory reporting.

Reliability Methodologies: MTTR & MTBR:

• Implement and govern Mean Time To Repair (MTTR) and Mean Time Between Repairs (MTBR) tracking across all critical assets within the electroplating facility.
• Analyze reliability data to identify chronic failure modes and prioritize corrective actions, equipment upgrades, or redesign initiatives.
• Develop and maintain asset criticality rankings to drive resource allocation decisions and PM schedule optimization.
• Present monthly reliability KPIs to plant leadership including MTTR trends, PM compliance rates, breakdown frequency, and maintenance cost per unit.
• Lead root cause analysis (RCA) investigations for significant unplanned downtime events and implement corrective and preventive actions (CAPA).
• Drive transition from reactive to proactive maintenance culture through structured reliability improvement plans.

Spare Parts Inventory Management:

• Establish and maintain a critical spare parts inventory strategy aligned with asset criticality and supplier lead times for all electroplating equipment.
• Define minimum/maximum stock levels, reorder points, and economic order quantities (EOQ) for electrical, mechanical, and chemical-process components.
• Manage storeroom organization, part numbering, and inventory accuracy through periodic cycle counts and annual physical inventories.
• Negotiate with suppliers and OEMs to secure preferred pricing, consignment arrangements, and emergency delivery agreements for high-criticality items.
• Collaborate with procurement and finance to manage inventory carrying costs while minimizing stock-out risk on production-critical components.
• Audit obsolescence of legacy parts tied to aging rectifiers, pumps, and ventilation equipment; facilitate planned replacement programs.

Work Order & CMMS Management:

• Administer the Computerized Maintenance Management System (CMMS) to capture, prioritize, assign, and close all corrective, preventive, and predictive work orders.
• Ensure full work order lifecycle documentation including labor hours, materials consumed, failure codes, and technician notes for asset history integrity.
• Develop and maintain a Master Preventive Maintenance (PM) schedule aligned to OEM recommendations, regulatory requirements, and production windows.
• Monitor open work order aging and backlog metrics; facilitate weekly maintenance planning meetings with operations to coordinate access and scheduling.
• Leverage CMMS data for budget forecasting, trend analysis, and continuous improvement initiatives.
• Train technicians and supervisors on proper CMMS utilization, data entry standards, and work order discipline.

Team Leadership & Safety Compliance:

• Recruit, develop, and lead a team of maintenance technicians across electrical, mechanical, and plumbing disciplines.
• Conduct regular performance reviews, set individual development goals, and champion skills training programs.
• Serve as a key stakeholder in facility safety committees; champion a zero-incident safety culture.
• Ensure all maintenance activities comply with OSHA, EPA regulations, and internal EHS policies.
• Develop and maintain maintenance department budget; manage capital and operating expenditures with accountability to plant financial targets.
• Coordinate contractor qualification, permitting, and supervision for outside maintenance services.

Qualifications:

• Bachelor's degree in one of the following Mechanical Engineering, Electrical Engineering, Industrial Technology, or a related technical discipline; equivalent combination of education and experience considered.
• Minimum 5 years of progressive maintenance experience in a heavy industrial or chemical manufacturing environment.
• Minimum 3 years in a maintenance supervisory or management role with direct team leadership responsibility.
• Demonstrated hands-on experience with DC rectifiers, high-amperage power systems, and associated electrical controls in an electroplating or similar electrochemical process environment.
• Proven experience managing process plumbing systems involving corrosive chemicals (acids, caustics, cyanides).
• Working knowledge of industrial ventilation design principles and LEV maintenance in a regulated chemical environment.
• Applied experience with MTTR and MTBR reliability methodologies and asset management frameworks.
• Proficiency with a CMMS platform for work order and PM management.
• Strong understanding of OSHA General Industry standards and EPA regulations applicable to electroplating facilities.
• Ability to read and interpret electrical schematics, P&IDs, mechanical drawings, and equipment manuals.
• Must have or wiliness to retain OSHA 10 certification.
• Must have or willingness to retain HAZWOPER 24 hr.

Preferred Qualifications:

• Certified Maintenance & Reliability Professional (CMRP) certification.
• Experience with predictive maintenance technologies (vibration analysis, thermography, ultrasonic testing).
• Six Sigma Green Belt or Lean Manufacturing certification.
• Experience with ISO 9001 Quality Management Systems.
• Prior involvement in capital project execution including equipment specification, vendor selection, and installation management.

Core Competencies:

• Technical Mastery: Knowledge of electroplating equipment, electrical systems, and process utilities
• Reliability Mindset: Data-driven approach to asset management with focus on uptime and cost control
• Safety Leadership: Unwavering commitment to regulatory compliance and zero-incident culture
• Team Development: Proven ability to build, coach, and retain high-performing maintenance teams
• Cross-functional Collaboration: Strong partnering with operations, EHS, engineering, and procurement
• Analytical Problem-Solving: Structured root cause analysis and continuous improvement orientation

Physical & Environmental Requirements:

• Ability to work in an active industrial environment with exposure to chemical fumes, and varying temperatures.
• Must be able to wear and work in appropriate PPE including chemical-resistant gloves, safety glasses, face shields, and respirators as required.
• Ability to stand, walk, and navigate plant floor for extended periods; occasional lifting up to 50 lbs.
• Availability for on-call response to critical equipment failures outside of standard business hours.
• Ability to work at heights as required.