Maintenance and Reliability Manager

REQUIREMENTS:


Experience:

• Minimum of 10+ years as a maintenance manager/reliability leader
• Working in a fast-paced production environment
• Mechanical aptitude a must
• PLC programming experience preferred
• Chemical Manufacturing maintenance and reliability experience
• Lean / Six Sigma Green Belt Required
• Excellent understanding and application of regulations and codes ASME, NFPA, OSHA, PSM, API, EPA
• Project planning, execution and personnel management required
• Demonstrated experience with asset reliability, root cause analysis, preventive and predictive maintenance programs.
• Experience managing maintenance budgets, contractors, capital projects, and technical resources.
• Strong knowledge of CMMS platforms, ERP systems, maintenance planning systems, and reliability analytics.

Education:

• Bachelor's Degree in Mechanical (preferred), Electrical or Chemical Engineering required

Skills:

• Strong mechanical engineering and equipment reliability expertise with demonstrated experience improving asset reliability, reducing downtime, and increasing OEE.
• Advanced troubleshooting and root cause analysis skills using structured methodologies such as RCA, 5-Why, Fishbone, FMEA, Fault Tree Analysis, and Reliability Centered Maintenance (RCM).
• Proven ability to analyze equipment performance data, failure trends, maintenance costs, and operational metrics to drive data-based decisions and capital recommendations.
• Experience developing and optimizing preventive, predictive, and condition-based maintenance programs.
• Strong understanding of rotating equipment, pumps, conveyors, filling systems, packaging equipment, pneumatic systems, hydraulic systems, compressors, and utility systems.
• Experience utilizing reliability tools and technologies including vibration analysis, thermography, oil analysis, ultrasonic inspection, and condition monitoring systems.
• Ability to identify chronic equipment losses and develop sustainable solutions that improve reliability, throughput, quality, and safety.
• Demonstrated project management skills, including capital project justification, budgeting, equipment installation, commissioning, FAT/SAT participation, and startup support.
• Strong understanding of maintenance planning, scheduling, spare parts optimization, CMMS systems, and work order management.
• Experience applying Lean Manufacturing, Six Sigma, TPM, and Continuous Improvement methodologies to improve operational performance.
• Knowledge of OSHA regulations, PSM requirements, NFPA standards, machine safety, LOTO, and engineering standards applicable to manufacturing operations.
• Strong analytical skills with proficiency in Excel, ERP systems, CMMS platforms, Power BI, and data visualization tools.
• Ability to collaborate effectively with Operations, Maintenance, Engineering, EHS, Quality, Procurement, and external contractors.
• Excellent communication and influencing skills with the ability to lead cross-functional teams without direct authority.
• Ability to operate effectively in a fast-paced manufacturing environment while managing multiple projects and competing priorities.
• Demonstrated ownership mindset with a passion for driving reliability, eliminating losses, and improving overall equipment performance.

DUTIES & RESPONSIBILITIES:

• 1. Asset Reliability & Equipment Performance
• Develop and implement the site's reliability strategy to improve OEE, reduce unplanned downtime, and increase asset availability.
• Establish, manage, and continuously improve preventive, predictive, and condition-based maintenance programs.
• Lead Root Cause Failure Analysis (RCFA) investigations and implement sustainable corrective actions.
• Analyze equipment performance, downtime trends, maintenance costs, and operational data to identify improvement opportunities.
• Develop long-term asset management, lifecycle cost, refurbishment, and replacement strategies.
• Drive data-based decision making for equipment upgrades, modernization initiatives, and capital investments.
• Establish asset criticality rankings and reliability improvement roadmaps.
• Continuously improve MTBF, MTTR, maintenance schedule compliance, and asset utilization.

• 2. Mechanical, Electrical, Instrumentation & Controls Systems
• Ensure reliability and performance of mechanical, electrical, pneumatic, hydraulic, and utility systems.
• Provide oversight of electrical distribution systems, motor control centers (MCCs), VFDs, power systems, and facility electrical infrastructure.
• Maintain reliability of instrumentation, sensors, transmitters, control valves, safety systems, and process monitoring equipment.
• Support the maintenance and lifecycle management of PLCs, HMIs, SCADA systems, industrial networks, and automation platforms.
• Lead troubleshooting of complex mechanical, electrical, controls, and automation failures.
• Develop equipment standards and maintenance strategies for critical electrical and control assets.
• Identify automation opportunities that improve safety, reliability, efficiency, and operational performance.

• 3. Mechanical Integrity & Regulatory Compliance
• Own the site's Mechanical Integrity Program and ensure compliance with applicable company standards and regulatory requirements.
• Ensure inspection, testing, maintenance, and certification of critical equipment, pressure systems, piping, utilities, process equipment, and fire protection systems.
• Support Process Safety Management (PSM), environmental compliance, and risk reduction initiatives.
• Ensure adherence to OSHA, EPA, NFPA, local codes, insurance requirements, and recognized engineering standards.
• Manage statutory inspections, audits, permits, corrective actions, and compliance documentation.
• Ensure process safety critical equipment maintains required levels of integrity and reliability.

• 4. Maintenance Planning, Scheduling & Execution
• Own and continuously improve maintenance planning, scheduling, and work management processes.
• Ensure effective use of CMMS, work order systems, preventive maintenance schedules, and maintenance reporting tools.
• Develop and maintain maintenance procedures, SOPs, job plans, and equipment care standards.
• Drive planning and execution excellence to maximize wrench time and maintenance productivity.
• Establish shutdown, outage, and turnaround maintenance strategies.
• Provide technical leadership during significant equipment failures and emergency maintenance situations.
• Ensure maintenance activities are completed safely, efficiently, and with minimal operational disruption.

• 5. Critical Spare Parts & Inventory Management
• Develop and manage critical spare parts strategies based on equipment criticality, business risk, and lead times.
• Ensure appropriate inventory levels are maintained for critical production, utility, safety, and process safety equipment.
• Partner with Supply Chain and Procurement to optimize inventory investment while minimizing operational risk.
• Monitor equipment obsolescence and develop mitigation strategies.
• Implement spare parts standardization and lifecycle management programs.

• 6. Maintenance Leadership & Talent Development
• Provide direct leadership for maintenance personnel, supervisors, reliability resources, and support staff.
• Establish clear performance expectations, goals, accountability measures, and development plans.
• Lead hiring, onboarding, coaching, succession planning, performance management, and employee development activities.
• Build a high-performance culture focused on safety, reliability, technical excellence, accountability, and continuous improvement.
• Develop technical competency programs, certification pathways, and structured training plans.
• Support Maintenance Supervisors in managing frontline maintenance technicians and mechanics.
• Develop future technical and leadership talent within the maintenance organization.

• 7. Contractor & Vendor Management
• Establish contractor safety, qualification, onboarding, and performance management processes.
• Manage relationships with OEMs, equipment suppliers, engineering firms, contractors, and service providers.
• Review and approve contractor scopes of work, technical specifications, bid packages, quotations, and service agreements.
• Monitor contractor performance through KPIs, SLAs, quality metrics, safety performance, and project deliverables.
• Ensure all contractors comply with site safety, environmental, quality, and operational requirements.
• Drive cost savings and performance improvements through strategic vendor partnerships.

• 8. Engineering & Capital Projects
• Lead maintenance and reliability aspects of capital projects from concept through startup and commissioning.
• Provide technical input for equipment selection, FAT/SAT reviews, installation, commissioning, and operational handover.
• Develop equipment standards, technical specifications, and engineering requirements for new projects.
• Partner with Engineering and Operations to implement equipment upgrades and capacity improvement projects.
• Prepare business cases, ROI analyses, and financial justifications for capital expenditures.
• Support equipment modernization and technology advancement initiatives.

• 9. Cross-Functional Leadership & Business Partnership
• Partner closely with Operations, Engineering, Quality, EHS, Finance, Procurement, and Supply Chain functions.
• Lead cross-functional teams focused on reliability improvements, loss elimination, process optimization, and operational excellence.
• Align maintenance priorities with production, quality, safety, service, and financial objectives.
• Act as the site's technical authority for reliability, maintenance, and asset management decisions.
• Effectively communicate risks, priorities, and recommendations to site leadership and executive management.

• 10. Continuous Improvement & Operational Excellence
• Lead TPM, Lean Manufacturing, Reliability-Centered Maintenance (RCM), Six Sigma, and continuous improvement initiatives.
• Establish maintenance excellence standards and asset care programs.
• Drive 5S implementation within maintenance and technical areas.
• Eliminate chronic equipment losses through structured problem-solving methodologies.
• Implement predictive maintenance technologies including vibration analysis, thermography, oil analysis, ultrasonics, and condition monitoring.
• Develop and maintain maintenance and reliability KPI dashboards.

• 11. Facilities & Utilities Management
• Ensure reliability and maintenance of facility infrastructure and utility systems.
• Manage maintenance strategies for electrical distribution, compressed air, HVAC, chillers, boilers, process cooling, wastewater, and fire protection systems.
• Support facility improvement projects and infrastructure reliability initiatives.
• Ensure utility systems can support current and future manufacturing requirements.

• 12. Financial & Asset Stewardship
• Develop and manage annual maintenance operating and capital budgets.
• Monitor maintenance spending, contractor costs, inventory investment, and project expenditures.
• Identify opportunities to reduce Total Cost of Ownership (TCO) while improving reliability and operational performance.
• Develop long-range asset replacement and capital investment plans.
• Ensure responsible stewardship of company assets and resources.

Responsibilites can be added based on Operations and Capital project needs.

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