Maintenance Manager

Purpose and Scope:

Primary responsibility is to function as a Maintenance and Facilities Manager which includes prioritizing projects and coordinating resources to meet business objectives while maintaining and improving systems and procedures. Lead the maintenance team to proactively maintain, troubleshoot, repair, calibrate, and improve equipment and the facilities in a timely manner to assure that production and uptime goals are met. Implement and continuously improve equipment maintenance utilizing the maintenance management software, and other systems.

Expected Outcomes/Job Functions:

Safety Expectations:

Responsible for department incident rate consistent with Blue Star Glass company goals. Must maintain department safety rules compliance and be a positive safety role model. Responsible for training all department employees on safe work practices. Responsible for ensuring an organized, clean and safe work environment. Responsible for team attendance at all monthly safety training meetings. Ensure procedures and work practices have appropriate safety review and new equipment is reviewed for proper guarding, safe operating procedures, and lockout tagout. Must have regular safety discussions with team and proactively listen to employees' safety concerns/suggestions. Must act upon those concerns and provide feedback. Responsible for implementing corrective actions after an incident or near miss. Must support department employees with time opportunities to perform extra-curricular safety programs (ie: 1st responders, safety meeting presenters, safety committee, audits). Responsible for leading team safety meetings within department.

Responsibilities:

Lead the maintenance and facilities needs by proactively maintain, troubleshoot, repair, calibrate, and improve equipment in a timely manner to assure that production and uptime goals are met. Support and assist operations to meet customer orders to ensure the finished products meet delivery dates and quality requirements. Lead and support multiple projects (facility and maintenance related) and assist others while handling multiple tasks in order to successfully meet all deadlines.

• Plan, organize, and execute projects for facilities and production work centers.
• Function as a project sponsor, leader, or team member as assigned or appropriate.
• Lead and manage large-scale projects. Lead large multi-disciplinary, cross-departmental teams.
• Document and communicate project status, engineering changes, and other information to managers, engineers, technicians and other Operations and support staff.
• Coordinate training on new production methods and monitor their implementation through auditing process.
• Provide equipment maintenance leadership utilizing proactive, preventative, and predictive maintenance methods and systems.
• Implement and coach others in Lean Maintenance, Six Sigma, TPM, and maintenance management software. Strive to be a world-class maintenance organization and exceed equipment uptime goals. Develop and maintain a work schedule that provides appropriate exposure to all shifts of direct reports.
• Proactively communicate business and department results (performance to established metrics, financial results, and general business information.)
• Ensure all necessary spare parts and components are identified, listed, and available. Ensure the spare parts system utilizes lean maintenance principles.
• Document and monitor procedures and processes to eliminate variation and promote sharing of knowledge.
• Learn, understand, and follow documented work procedures, including maintenance, operational and troubleshooting procedures, such as daily checklists and basic glass washer, sand blaster, and overhead crane set-up, operation and repair procedures and related paperwork.

Lead team to:

• Ensure maintenance coverage is provided on a 7-day, 24-hour basis.
• Perform maintenance and set-up on all equipment and systems according to established procedures in a proactive quality-sensitive manner with the objective to improve coater uptime and performance.
• Provide electronic, controls, and mechanical troubleshooting expertise to assist operations and reduce unscheduled downtime to established goals. Provide leadership to urgently troubleshoot and repair equipment.
• Diagnose and repair all electrical, electronic, and control software related failures on production equipment. Ensure all equipment software is properly backed-up, stored, and identified.
• Learn, maintain, and upgrade software packages and control area network systems and software to ensure full utilization of programmable devices such as PLC's, Servo's, Digital Process Controllers, Robots, etc.
• Ensure there is a plant electronic and mechanical equipment calibration (metrology) program to ensure accurate process control parameters.
• Ensure knowledge transfer for coater setups, cathode rebuilding, and maintenance for cathodes, cathode targets, and target tubes to limit downtime.
• Keep work areas, shops, and spare parts area in a neat and orderly condition utilizing tools of 6S.
• Communicate with all team members and leaders to assure efficient completion of maintenance activities and projects and eliminate dropped issues or duplicated efforts.
• Communication includes shift change communication and written updates to leaders regarding projects and downtime events as well as participating in team problem solving methods.
• Communication to team members includes frequent in-person communication, e-mail and other written communications, and regular, frequent team meetings.

Training and development:

• Continue to cross train equipment technicians to mechanical and electronic tasks to increase skill and flexibility of each team member and the team as a whole.
• As part of TPM, provide leadership and guidance for cross training equipment technicians and production operators. Production staff shall be trained to perform simple maintenance tasks and equipment technicians shall be able to perform basic production tasks.
• Provide frequent, specific performance feedback and coaching to reports, including completing reviews thoroughly and on time. Proactively address individual or team performance issues.

Interact and function effectively in a high performance team environment and coach others in effective team interaction and function. Foster a "How can I help you?" environment. Initiate, drive, and support continuous improvement and elimination of waste and variation in processes using established improvement processes. Establishing and maintaining budgets for facility and production work centers and ensure lean maintenance methods are utilized to eliminate waste. Provide specific support and training for other departments as requested.

The above responsibilities represent the major tasks assigned to incumbents in this job title. They are not intended to be an exhaustive list of all tasks. Therefore, on occasion, incumbents may perform other related tasks.

Minimum Qualifications

• Able to use maintenance software (TBD) to document all work. Knowledge of Microsoft Office products (Word, Excel, Outlook).
• Able to write SOP's and review for edits and technical accuracy.
• General fabrication skills such as welding (ARC, MIG & TIG), torch, cutting equipment, grinders, and able to follow simple blue prints.
• Able to obtain and maintain current license for powered industrial equipment.
• Able to perform complex plumbing installation and repairs.
• Able to use mechanical measuring devices and complex testing equipment (Strip Chart Recorder, O-scope, VOM, pH and Conductivity meters) and perform calibrations as required.
• Able to identify programming problems related to programmable devices such as PLC's, Servo's, Digital Process Controllers, Robots, etc., and diagnose and assist in repairing deficiencies.
• Able to read basic electrical blue prints and meters.
• Able to troubleshoot without direct supervision and train others in troubleshooting.
• Able to learn Lean Sigma and Continuous Improvement techniques to improve overall plant operations (safety, quality, productivity, OEE).

Education and Experience: (minimum requirements)

Bachelor's degree required. Proven direct leadership experience. Minimum of (5) five years leadership experience in a manufacturing environment preferred. Demonstrated leadership, communication, and team building skills. 3 to 5 years of facility management or facility maintenance Robot/Automation knowledge is preferred. Proven proactive preventative and predictive maintenance experience and results. Demonstrated ability in mechanical and electrical trouble shooting and repair. Specific knowledge of Lean Maintenance and/or Production, Six Sigma, and TPM systems preferred. 5 years vacuum and/or coating experience strongly preferred. Demonstrated ability to learn and adapt to new technology types.

Attributes:

1. Strong project coordination and communication skills.
2. Awareness of general operating standards for mechanical and electric/electronic systems to recognize and anticipate likely problems before they become critical.
3. Excellent troubleshooting and diagnostic skills to define problems and resolve them quickly.
4. Clear sense of urgency and ability to manage priorities to meet immediate needs and long-term goals. High sensitivity to quality and on time delivery of materials and services.
5. Demonstrated ability to work and cross train in a team environment. Sensitive to other cultures and backgrounds, able to work in a diverse workplace.
6. Ability to lead and develop others, coach and effectively motivate others in a positive manner.
7. Ability and willingness to learn, understand, and follow documented work procedures, and to create new documentation.
8. Ability, willingness and commitment to develop and maintain effective communications and relationships with technicians and other employees on all shifts.

Physical Demands:

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. For specific lifting, pushing and pulling thresholds for this position, please see HR.

While performing the functions of this job, the employee is regularly required to sit, stand, walk, talk, and hear. The employee is frequently required to use hands and fingers to feel, handle, or operate objects, tools, or controls; and reach with hands and arms. The employee may occasionally lift and/or move up to 30 pounds. Vision requirements include close vision, color vision, and the ability to adjust focus.

Communication Expectations:

The position routinely requires verbal and written communication in English in order to complete the daily business requirements. Verbal communications include, but are not limited to: team meetings to discuss daily department requirements, work instructions to team members, presentations to management or customers, project meetings with peers and management, communications with peers and management, and safety instructions and training. Written communications include, but are not limited to: department paperwork, projects updates, safety walkthroughs, purchase orders, continuous improvement projects, and communications with peers, customers, and management.

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