Maintenance Manager

Description

The Maintenance Manager is responsible for leading the plant maintenance function and developing a reliable, disciplined maintenance system that supports safe and consistent manufacturing operations. The primary objective of this role is to transition the organization from a primarily reactive maintenance environment toward planned, preventive, and reliability-focused maintenance.

The successful candidate will quickly assess equipment condition and current maintenance practices, identify critical equipment and operational risks, establish preventive maintenance and work-management fundamentals, develop a critical spare-parts strategy, improve maintenance purchasing controls, and use downtime and failure data to drive continuous improvement. This is a hands‑on leadership position requiring strong technical judgment, organization, follow‑through, and partnership with Operations.

• Assess the current condition, reliability, and maintenance needs of plant equipment.
• Develop and execute a plan to transition maintenance from reactive breakdown response toward planned and preventive maintenance.
• Establish practical maintenance standards, routines, priorities, and follow‑up processes.
• Use equipment history, operating conditions, OEM recommendations, and failure data to improve maintenance strategies.
• Identify chronic equipment issues and drive permanent corrective actions rather than repeated temporary repairs.

• Develop and maintain a critical‑equipment list based on safety, production, quality, delivery, redundancy, repair time, and parts availability.
• Establish equipment criticality rankings or tiers to guide maintenance priorities and resources.
• Develop reliability plans for critical assets, including preventive maintenance, common failure modes, critical spare parts, vendor support, and recovery plans.
• Identify single points of failure and communicate significant equipment risks to plant leadership.
• Support repair‑versus‑replace and capital planning decisions using equipment condition and reliability data.

• Evaluate existing preventive maintenance activities and identify gaps.
• Develop preventive maintenance procedures and frequencies for equipment where adequate PMs do not exist.
• Coordinate PM schedules with Production to minimize disruption while protecting equipment reliability.
• Track PM completion and compliance, address overdue work, and verify that PM activities are effective.
• Introduce predictive or condition‑based maintenance methods where appropriate.

• Establish consistent equipment for downtime tracking and reporting.
• Analyze downtime by asset, failure type, cause, repair duration, labor, and parts used.
• Use Pareto analysis and other problem‑solving methods to identify the plant's largest reliability losses.
• Lead or support root cause analysis for significant and recurring equipment failures.
• Assign corrective actions, verify completion, and confirm that actions prevent recurrence.

• Identify critical spare parts by equipment and determine which parts should be stocked onsite.
• Establish appropriate minimum/maximum quantities, reorder points, and stocking strategies based on criticality, cost, failure frequency, availability, and supplier lead time.
• Maintain accurate part descriptions, OEM and alternate part numbers, equipment associations, and preferred suppliers.
• Identify obsolete or difficult‑to‑source components and develop risk‑mitigation or replacement plans.
• Reduce emergency purchasing, unnecessary expedited freight, and avoidable stockouts while maintaining appropriate inventory…