Maintenance Manager

Maintenance Manager

The Maintenance Manager is responsible for leading and supervising all maintenance activities to ensure safe, reliable, and efficient operation of plant equipment, utilities, and facilities. This role drives preventive and predictive maintenance strategies, manages maintenance personnel and contractors, controls the maintenance budget, and ensures compliance with safety, environmental, and quality standards. The Maintenance Manager plays a key role in minimizing downtime, extending asset life, and supporting production performance.

Essential Functions and Responsibilities:

1. Equipment & Facility Reliability

• Ensure maximum uptime and reliability of all production, utilities, and facility systems.
• Develop, implement, and continuously improve preventive and predictive maintenance programs.
• Lead troubleshooting, root cause analysis, and permanent corrective actions for recurring failures.

1. Maintenance Planning & Execution

• Plan, schedule, and prioritize maintenance work orders in coordination with Production.
• Balance emergency, corrective, and preventive maintenance activities.
• Ensure all work is executed safely, efficiently, and on schedule.

1. Team Leadership & Development

• Supervise, develop, and mentor the maintenance team.
• Assign work, evaluate performance, and ensure required training and certifications.
• Promote a strong culture of safety, accountability, and continuous improvement.

1. Safety, Compliance & Standards

• Ensure full compliance with OSHA, environmental regulations, and company policies.
• Lead safety initiatives related to equipment, lockout/tagout (LOTO), and machine guarding.
• Participate in plant audits (safety, insurance, regulatory).
• Act as Safety Coordinator during workplace emergencies.
• Immediately address any incidents / accidents in the workplace which cause harm or injury to the environment and/or personnel.

1. Budgeting & Cost Control

• Participate with the Plant Manager in the preparation of the annual maintenance budget.
• Control maintenance costs (labor, spare parts, contractors, capital repairs) while maintaining equipment performance and safety.
• Support capital planning for new equipment, upgrades, and plant expansions.

1. Spare Parts & Inventory & Maintenance Software Management

• Define critical spare strategies based on FMEA risk analysis.
• Ensure all parts, preventive maintenance, corrective maintenance, and work orders are accurately managed within the Computerized Maintenance Management System (CMMS).
• Maintain the integrity of the CMMS parts database (min/max levels, vendors, lead times, equipment linkage).
• Optimize inventory and manage service contracts and spare part suppliers.

1. Preventive and Predictive Maintenance (PM/PdM) Program

• Define PM frequencies based on OEM guidance, equipment criticality, failure history and FMEA analysis.
• Monitor PM compliance and optimize maintenance plans using Mean Time Before Failures (MTBF) and breakdown trends.
• Implement predictive tools where applicable (vibration, thermography, oil analysis).
• Ensure all PM and CM activities are fully managed, scheduled, executed, and documented within the CMMS.

1. Capital Projects & Improvements

• Support installation, commissioning, and startup of new equipment.
• Collaborate with Engineering, Production, and Quality on equipment upgrades and process improvements.

1. Performance Metrics & Reporting

• Track and report KPIs (downtime, MTBF, PM compliance, vs. budget, etc.).
• Use data to drive reliability and continuous improvement.

1. Other responsibilities as assigned by the Plant Manager.

Minimum Qualifications:

1. Bachelor's degree in engineering, Industrial Maintenance, or related field (or equivalent experience).
2. 5+ years of maintenance leadership experience in a manufacturing or industrial environment.
3. Experience in continuous extrusion process and/or mechanical and pneumatic conveying systems preferred.
4. Abilities to read and understand process flow and shop drawings.
5. Strong knowledge of:

• Mechanical, pneumatics, hydraulics, and electrical systems
• PLCs and automation (preferred)
• Preventive and predictive maintenance programs

1. Strong troubleshooting, planning, and organizational abilities.
2. Proven leadership and team management skills.
3. Proficient in Microsoft Office.
4. Knowledge of OSHA regulations, machine safety standards, and environmental compliance requirements.
5. Demonstrated knowledge of PPE requirements, selection, use, and regulatory compliance.

Working Conditions and/or Physical Demands:

1. Must be able to wear required PPE at all times.
2. Must be able to traverse property and facility to diagnose building issues and plan repairs or maintenance.
3. Must be physically able to perform repairs when needed.
4. Ability to work in tight spaces, heights and environmentally unfriendly conditions.
5. Available on call outside regular working hours.

Reports to the Plant Manager.