Maintenance Manager

DUTIES AND RESPONSIBILITIES

• The incumbent is responsible for leading and changing the maintenance organization for both equipment and facilities.
• Must establish and drive systems and measurements required for the maintenance department to succeed
• Responsible for supporting the entire organization in reducing scrap, solving or eliminating customer complaints, and optimizing and stabilizing the processes used in the plant
• Must use strong safety and quality orientations and methods to drive safety, quality, productivity, people improvement and results through engineering and maintenance innovation
• Set and achieve both long- and short-term goals and objectives for the maintenance department with the primary focus on reducing and eliminating process variation, achieving greater process stability, higher production uptime, greater machine speed, and greater autonomation.
• Drive development of innovations to improve machinery process performance, and fully support the development and effective production of new product designs, effective machine capabilities, and technology transfers from the HQ
• Drive TPM efforts to yield higher productivity and improve autonomation.
• Understand financial objectives; meet or exceed financial performance targets (i.e. scrap and downtime); participate in forecasting and financial analysis; manage capital projects including writing and completing RFAs.
• Manage and lead multiple projects that support all aspects of the manufacturing process
• Create a learning organization, providing cross-training to individuals to ensure that they stay abreast of the latest manufacturing technologies
• Suggest capital improvement projects that will improve efficiency, productivity, and capability
• Lead capital improvements while maintaining RFA budget requirements; excellent knowledge of financial and cost analysis techniques \
• Practice safe work habits while holding the department staff accountable for safety expectations proactively monitors and completes administrative tasks, such as monthly budgets, required monthly reporting, and operational excellence requirements
• Oversee the collection of and utilization of data to analyze for improvement of MTBF and MTT
• Expert at troubleshooting all aspects of injection and compression molding equipment
• Provide data-driven responses to equipment issues while following through on priorities and requirements
• Proactively use data to problem-solve chronic equipment issues with injection molding while utilizing sound engineering and reliability principles
• Effective managerial leadership skills and the ability to lead organizational change processes to improve worker attitudes, involvement and organizational results
• Strong working knowledge of company policies and standards in the areas of safety, personnel, quality, and manufacturing
• Highly developed communications skills, both verbal and written
• Coordinates efforts with the Beta Test Team/ATB personnel to transition new or improved equipment to the plant floor.
• Understands and utilizes statistical process control (SPC) and quality tools (i.e. problem-solving strategies, root cause analysis, TQM, ISO 9000, SOP Process, etc.) to improve processes, maximize yield, and reduce costs
• Consequence management for staff performance metrics
• Improves processes to reduce scrap and defects while improving throughput.
• Provides expert troubleshooting on process issues and determines appropriate courses of action to improve quality, cost, and maintain a safe work environment.
• Performs analyses on existing equipment using sound engineering principles and reliability-based methods to identify ways to extend equipment MTBF.
• Understands customer’s needs, the corresponding product features designed to meet those needs, and the capabilities of the process.
• Successful implementation of new products and processes.
• Training in the appropriate use of problem solving and quality tools and utilizes them to obtain cost and quality improvements.

SUPERVISORY RESPONSIBILITIES

Direct Reports:

Maintenance Supervisor, Crib Attendant, Facilities Coordinator, Maintenance Planner

Indirect Reports: roughly 40 hourly maintenance employees

EDUCATIONAL AND OTHER SKILL REQUIREMENTS

• Bachelor’s Degree in appropriate discipline and/or equivalent experience.
• 5-10+ years working in Engineering &/or Maintenance management in a Manufacturing Environment.
• Six Sigma & FMEA training required; uses six sigma & FMEA principles on the job
• Prefer experience with both compression and injection molding processes, experience with plastics technology.
• Experience working with critical tolerance measurements and delivering high-tolerance results in a fast-paced manufacturing environment. Thorough understanding of all process and auxiliary equipment (liners, scoring, DESCO printers, laser printers, image).
• Experience with successfully passing third party audits such as ISO, AIB, Milk Shippers, specific customer audits. Prefer candidates with experience in Good Manufacturing Practices for the food industry as well as HACCAP.
• Knowledge of Operational Excellence (OPEX) techniques and/or experience with continuous improvement techniques such as, but not limited to Process Flow Design, FMEA, Poke Yoke, Standardized Work, TPM, etc. Computer experience using Windows based software, such as Word, Excel, Visio, MS Project.
• Organizational and prioritization skills.
• Demonstrates strong team skills, and team leadership skills.
• Training and communication skills.
• Critical Thinking and Forward Thinking.
• Strong results orientation.