Maintenance Manager

Maintenance Manager

REPORTS TO:                       Plant Manager

DIRECT REPORTS: Maintenance Supervisor and Maintenance Planner

FLSA STATUS:         Exempt

ROLE:

The Maintenance Manager is responsible for overseeing the maintenance requirements of production, facility, and utilities for a 24/7 manufacturing environment. Design, implement and manage programs for effective maintenance operations.

Responsibilities are to be completed with consideration of safety, cost, efficiency, timeliness, and production of a quality product within specifications. This is a highly collaborative position requiring strong organizational, follow up and communication skills.

ESSENTIAL DUTIES AND RESPONSIBILITIES

• Establish plans which support company maintenance and performance objectives and communicate these effectively to the plant teams and all levels of employees.
• Provide technical guidance and expertise to aid in the accomplishment of objectives and develop a knowledgeable and efficient maintenance team.
• Identify and lead root cause analysis of maintenance failures.
• Support problem resolution and decision-making.
• Manage reliability requirements as determined by the Corporate Reliability Manager.
• Establish systems to collect data, analyze productivity and set targets to meet department goals
  • Changeover targets
  • Overall Equipment Efficiency
• Establish and meet corporate key performance indicators
• Assist with preparation and management of maintenance budgets to meet set objectives.
• Implement and utilize visual and structured communications through a well implemented and sustained Tier process.
• Establish an environment that prioritizes the response to outages and the restoration of equipment functionality.
• Ensure utilization of Computerized Maintenance Management System (CMMS), LEAN tools and computer applications to:
• Improve Operational Equipment Efficiencies (OEE) percentages and reduce equipment downtime.
• Track key performance indicators on an ongoing basis.
• Identify and communicate issues to plant management.
• Implement appropriate corrective actions to deliver departmental results.
• Identify predictive maintenance opportunities and ensure timely completion of changeovers, set-up, and preventative maintenance requirements
• Maintain accurate records of maintenance operations
• Support management and prioritization of work orders

• Use a comprehensive and methodical project management approach to ensure successful implementation from inception through to completion.
  • Prepare and present timelines and budgetary requirements.
  • Manage internal and external participants for successful completion of objectives, through project status meetings focused on on-time and on-budget delivery.
    • Work directly with Original Equipment Manufacturers (OEMs)
    • Maintain Operations team involvement with and knowledge of the project through effective communications including status and debriefing meetings.
  • Manage and develop a highly skilled maintenance staff that is process driven and excellence motivated.
    • Hire and train a team of maintenance employees to conduct a full range of responsibilities at the manufacturing site.
    • Identify roles and responsibilities with the maintenance department.
    • Coach and develop existing employees within a pay-for-skills environment.
    • Identify, implement, and manage effective training programs and procedures in the maintenance area and ensure training requirements are met.
    • Develop employees for next level opportunities to ensure your and their progression within the organization.
      • Conduct timely skills evaluations.
      • Translate plant goals into functionaland individual goals.
    • Facility maintenance and monitoring that is focused on providing a safe and work friendly environment at an acceptable cost.
      • Maintain improvement year over year in kWh per finished good pounds.
      • Through the application of LEAN tools such as 5S and Gemba walks, supervise the activities of the building/utility/mech upkeep ensuring personnel maintain a clean and orderly facility.
      • Ensure that employee work and non-work areas are structurally sound, functional, safe, and environmentally compliant
      • Manage and monitor the completion of day-to-day maintenance responsibilities.
      • Perform daily and weekly inspection of facility to ensure smooth Operations.
      • Demonstrate a year over year improvement on Maintenance Scorecard as evaluated during Operations Review process.
    • Monitor costs and expenses to meet budget goals and ensure optimal cost effectiveness.
    • Promotes knowledge sharing across the facilities to fully leverage innovation and process improvements.
      • Actively participate in and support plant flex scheduling program.

TECHNICAL COMPETENCIES:

Project Management:

• Ability to identify, oversee, coordinate and/or support continuous improvement projects from conception through to implementation
• Yearly Capex planning and management.

Interpersonal/Communication:

• Demonstrates the servant leadership values of valuing people, humility, listening, trust and caring toward the employees under their stewardship.
• Demonstrates a high level of responsiveness to employee concerns and ideas for improvement.
• Ability to participate and/or foster interdepartmental communication and teamwork.
• Ability to prioritize multi-task duties without loss of efficiency or composure.
• Effective written and verbal communication and the ability to disseminate information in a timely and diplomatic manner.
• Ability to work under pressure, meet scheduled deadlines, respond to emergency situations without loss of efficiency or composure.
• Communicate regularly and pro-actively with upper management regarding problems or issues impacting equipment maintenance.
• Ability to establish and build relationships with internal/external customers.
• Ability to utilize professional negotiations skills and training.

Technical Knowledge:

• Demonstrates familiarity with:
• precision maintenance tooling to include precision laser alignment, torque wrenches
• thermoforming and extrusion equipment
• industrial support equipment
• Demonstrates fundamental understanding of polymer processing to include extrusion and thermoforming.
• Ensure asset reliability through TPM, Lean, Autonomous Maintenance, Root Cause Analysis, and other reliability tools.
• Ability to analyze and apply knowledge of machine/equipment capabilities to maximize production schedules.
• Demonstrates a fundamental understanding of standard manufacturing business processes.

Efficiency:

• Demonstrate ability to initiate and perform root cause analysis and implement corrective action to drive improvement.
• Ability to meet or exceed performance standards and continuously improve upon them.

Quality:

• Ensure compliance with GMP, SPC and SQF requirements within the department.

Compliance & Regulatory:

• Maintain required records and documentation, as related to safety training, NFPA compliance, environmental regulations, preventative maintenance for internal/external audit requirements including EPA, OSHA, SPC, GMP, SQF and customer specific (Panda Express, Yum).

Safety:

• Demonstrated ability to comply with all Company policies and procedures and to uphold, support and exemplify the safety programs and standards.
• Demonstrated understanding of the key components that comprise an effective plant wide safety program along with the ability to lead, develop and drive world class safety performance.
• Ensure department is compliant with company, OSHA, EPA, local, state, and federal and standards.

EDUCATION & EXPERIENCE:

• Minimum of 5 years of experience in a managerial or supervisory position.
• Education or a degree in a relevant field a plus.
• Knowledge of the Plastics Industry processes and equipment, specifically extrusion and thermoforming.
• Knowledge of raw material and production supplies utilized in the production of finished goods.
• Knowledge of MS Office and familiarity with database applications.
• Basic understanding of plastic physical properties and behaviors

ADA – ESSENTIAL FUNCTIONS:

Must be able to:                                                                                                                                              

• Work an 8-hour shift with overtime as required.
• Stand and/or walk constantly, sit frequently
• Speak and hear constantly
• Use of fingers, hands, and arms constantly
• Additional information can be found on the job specific Job Profile Medical Assessment

This job description is not intended to be a complete list of all responsibilities, duties or skills required for the job and is subject to review and change at any time, with or without notice, in accordance with the needs of Genpak LLC. Since no job description can detail all the duties and responsibilities that may be required from time to time in the performance of a job, duties and responsibilities that may be inherent in a job, reasonably required for its performance, or required due to changing nature of the job shall also be considered part of the jobholder’s responsibility.

The Maintenance Manager is responsible for overseeing the maintenance requirements of production, facility, and utilities for a 24/7 manufacturing environment. Design, implement and manage programs for effective maintenance operations.

Responsibilities are to be completed with consideration of safety, cost, efficiency, timeliness, and production of a quality product within specifications. This is a highly collaborative position requiring strong organizational, follow up and communication skills.

ESSENTIAL DUTIES AND RESPONSIBILITIES

• Establish plans which support company maintenance and performance objectives and communicate these effectively to the plant teams and all levels of employees.
• Provide technical guidance and expertise to aid in the accomplishment of objectives and develop a knowledgeable and efficient maintenance team.
• Identify and lead root cause analysis of maintenance failures.
• Support problem resolution and decision-making.
• Manage reliability requirements as determined by the Corporate Reliability Manager.
• Establish systems to collect data, analyze productivity and set targets to meet department goals
  • Changeover targets
  • Overall Equipment Efficiency
• Establish and meet corporate key performance indicators
• Assist with preparation and management of maintenance budgets to meet set objectives.
• Implement and utilize visual and structured communications through a well implemented and sustained Tier process.
• Establish an environment that prioritizes the response to outages and the restoration of equipment functionality.
• Ensure utilization of Computerized Maintenance Management System (CMMS), LEAN tools and computer applications to:
• Improve Operational Equipment Efficiencies (OEE) percentages and reduce equipment downtime.
• Track key performance indicators on an ongoing basis.
• Identify and communicate issues to plant management.
• Implement appropriate corrective actions to deliver departmental results.
• Identify predictive maintenance opportunities and ensure timely completion of changeovers, set-up, and preventative maintenance requirements
• Maintain accurate records of maintenance operations
• Support management and prioritization of work orders

• Use a comprehensive and methodical project management approach to ensure successful implementation from inception through to completion.
  • Prepare and present timelines and budgetary requirements.
  • Manage internal and external participants for successful completion of objectives, through project status meetings focused on on-time and on-budget delivery.
    • Work directly with Original Equipment Manufacturers (OEMs)
    • Maintain Operations team involvement with and knowledge of the project through effective communications including status and debriefing meetings.
  • Manage and develop a highly skilled maintenance staff that is process driven and excellence motivated.
    • Hire and train a team of maintenance employees to conduct a full range of responsibilities at the manufacturing site.
    • Identify roles and responsibilities with the maintenance department.
    • Coach and develop existing employees within a pay-for-skills environment.
    • Identify, implement, and manage effective training programs and procedures in the maintenance area and ensure training requirements are met.
    • Develop employees for next level opportunities to ensure your and their progression within the organization.
      • Conduct timely skills evaluations.
      • Translate plant goals into functionaland individual goals.
    • Facility maintenance and monitoring that is focused on providing a safe and work friendly environment at an acceptable cost.
      • Maintain improvement year over year in kWh per finished good pounds.
      • Through the application of LEAN tools such as 5S and Gemba walks, supervise the activities of the building/utility/mech upkeep ensuring personnel maintain a clean and orderly facility.
      • Ensure that employee work and non-work areas are structurally sound, functional, safe, and environmentally compliant
      • Manage and monitor the completion of day-to-day maintenance responsibilities.
      • Perform daily and weekly inspection of facility to ensure smooth Operations.
      • Demonstrate a year over year improvement on Maintenance Scorecard as evaluated during Operations Review process.
    • Monitor costs and expenses to meet budget goals and ensure optimal cost effectiveness.
    • Promotes knowledge sharing across the facilities to fully leverage innovation and process improvements.

Actively participate in and support plant flex scheduling program