Facility Maintenance Manager

Location:

Grand Prairie, TX

Company:
Qual Pac

Customer Site:
Frito-Lay (Dedicated Facility)

Facility Size: 250,000 sq ft

Operation: 3 shifts | 6 days/week | 3 automated lines + 4 manual lines

Qual Pac is seeking a highly capable and people‑focused Facility Maintenance Manager to lead all maintenance operations at our dedicated Frito‑Lay contract packaging facility in Grand Prairie, TX.

This role is responsible for both:

• Facility Maintenance & Infrastructure
• Automated Packaging Equipment Reliability & Performance

The site produces approximately 10 million cases annually of snack variety packs and is transitioning to a high‑volume, 3‑shift automated operation. The Maintenance Manager will oversee a team of approximately 6 maintenance technicians and ensure maximum uptime, safety compliance, and strong customer partnership performance.

This is a hands‑on leadership role requiring strong technical expertise, structured maintenance systems management (WMS/PMMS), and excellent team development capabilities.

• Maintenance Leadership & Team Development
• Lead, coach, and develop a team of 6 maintenance technicians.
• Establish clear performance expectations and accountability standards.
• Build technical capability through structured training and cross‑training.
• Create a culture of safety, ownership, and urgency around equipment reliability.
• Support 3‑shift coverage planning and escalation protocols.
• Provide escalation support outside normal hours as needed in a 24/6 operation.

• Case erectors
• Robotic picking systems
• Case packers
• Case sealers
• Robotic palletizers
• Printers and label systems
• Scales
• Date coders
• Conveyance systems

Responsibilities include:

• Developing and executing Preventive Maintenance (PM) programs
• Driving predictive maintenance initiatives
• Root cause analysis (RCA) for recurring failures
• Reducing unplanned downtime
• Managing spare parts strategy
• Supporting line changeovers and automation optimization
• Serve as primary technical escalation point for complex mechanical, electrical, PLC, and robotic system failures.
• Personally lead troubleshooting efforts during critical production downtime events

• Dock doors & levelers
• Overhead fans
• Bathrooms & break rooms
• Ice machines
• Safety systems
• General building upkeep
• AIB readiness & sanitation compliance
• Lighting & facility infrastructure

• Audit‑ready at all times
• Compliant with AIB and food safety standards
• OSHA and safety regulation compliant
• Champion equipment safety protocols and LOTO procedures.
• Ensure all automated systems meet safety standards.
• Maintain documentation and compliance records.
• Partner with Safety and Operations teams to eliminate hazards.
• Conduct safety audits and corrective actions.

• Ensure full utilization of WMS/PMMS system for:
• Work Orders (WOs)
• Preventive Maintenance (PMs)
• Parts inventory control
• Asset tracking
• Drive data accuracy and technician adoption.
• Develop KPI dashboards around:
• Uptime
• MTBF / MTTR
• PM compliance
• Parts spend
• Use system data to improve reliability and cost control.

• Maintain strong professional working relationship with customer leadership.
• Respond to facility and equipment needs with urgency.
• Support customer automation initiatives and expansion efforts.
• Participate in site reviews and performance discussions.

• Equipment uptime and OEE improvement
• PM completion rate (>95%)
• Reduction in reactive work orders
• Safety incident reduction
• AIB audit performance
• Maintenance cost control
• Team retention and engagement

• 5+ years of maintenance leadership experience in manufacturing or packaging.
• Experience managing automated packaging lines and robotics.
• Strong mechanical, electrical, pneumatic, and PLC troubleshooting skills.
• Proven experience implementing or managing a CMMS/PMMS system.
• Demonstrated ability to lead and develop maintenance technicians.
• Deep knowledge of equipment safety standards and LOTO compliance.
• Experience in food or consumer packaged goods (CPG) environment preferred.
• Strong organizational and communication skills.