Industrial Maintenance Lead

Industrial Maintenance Lead

The Industrial Maintenance Lead is responsible for leading the daily maintenance operations of the manufacturing facility by coordinating preventive maintenance, corrective repairs, equipment reliability, and facility maintenance activities. This position provides technical leadership and direction to the Maintenance Technician team to ensure all production equipment, utilities, and facility systems operate safely, efficiently, and reliably. The Industrial Maintenance Lead serves as the department's technical expert for mechanical, electrical, pneumatic, hydraulic, and control systems. This role coordinates maintenance work orders through the Computerized Maintenance Management System (CMMS), prioritizes reactive and preventive maintenance activities, oversees contractor work, and partners with Production, Engineering, Quality, and the Setup Team to maximize equipment uptime and Overall Equipment Effectiveness (OEE).

Unlike the Setup Lead, whose primary responsibility is production line changeovers and equipment setup, the Industrial Maintenance Lead is responsible for maintaining and restoring equipment reliability, reducing equipment failures, improving preventive maintenance programs, and ensuring long-term asset performance.

Essential Duties and Responsibilities

Maintenance Leadership

• Lead the daily activities of the Maintenance Department and assign work based on production priorities and equipment needs.
• Coordinate corrective, preventive, and predictive maintenance activities.
• Monitor maintenance workloads and adjust priorities to minimize production downtime.
• Provide technical guidance and support to Maintenance Technicians.
• Promote a safe, productive, and collaborative work environment.
• Assist the Maintenance Supervisor with departmental planning and scheduling.
• Ensure maintenance work is completed safely, efficiently, and according to established standards.

Preventive and Predictive Maintenance

• Coordinate and schedule preventive maintenance using the CMMS.
• Review completed preventive maintenance activities for accuracy and completeness.
• Develop and improve preventive maintenance procedures to increase equipment reliability.
• Identify recurring equipment failures and implement permanent corrective actions.
• Support predictive maintenance initiatives including vibration analysis, thermal inspections, lubrication programs, and equipment condition monitoring when applicable.
• Ensure maintenance schedules minimize production interruptions while maximizing equipment availability.

Equipment Reliability

• Maintain and repair manufacturing equipment including but not limited to: Liquid fillers, Tube fillers, Bottle unscramblers, Bottle cappers, Cap sorters, Induction sealers, Pressure-sensitive labelers, Shrink sleeve applicators, Cartoners, Case packers, Conveyors, Checkweighers, Inkjet and laser coding systems, Vision inspection systems, Pumps, Mixers, Compressors, Facility support equipment.

Mechanical and Electrical Maintenance

• Lead and perform maintenance involving: Mechanical systems, Electrical systems, Hydraulic systems, Pneumatic systems, Variable Frequency Drives (VFDs), AC and DC motors, Motor controls, Sensors, Photo eyes, Load cells, Solenoid valves, Gearboxes, Bearings, Chains and sprockets, Conveyors, PLC-controlled equipment (mechanical support and diagnostics).

Troubleshooting

• Lead complex troubleshooting activities involving: Mechanical failures, Electrical faults, Pneumatic leaks, Hydraulic failures, Motor failures, Conveyor issues, Sensor failures, PLC-related equipment faults (coordinate with controls personnel as required), Utility failures, Production equipment breakdowns.
• Perform Root Cause Analysis (RCA) and develop corrective actions that eliminate recurring failures.

CMMS Administration

• Utilize the Computerized Maintenance Management System (CMMS) to: Create work orders, Prioritize maintenance requests, Assign work to technicians, Track labor hours, Record repair history, Document equipment failures, Monitor preventive maintenance compliance, Maintain equipment maintenance records.
• Ensure all maintenance documentation is accurate and completed in a timely manner.

Spare Parts and Inventory

• Maintain critical spare parts inventory.
• Recommend inventory levels based on equipment criticality.
• Submit purchase requisitions for maintenance materials and replacement parts.
• Work with Purchasing to ensure timely availability of repair components.
• Maintain organization of the maintenance shop and spare parts storage areas.

Contractor Coordination

• Coordinate outside contractors performing maintenance, repairs, installations, and capital improvement projects.
• Verify contractors comply with company safety policies, GMP requirements, and facility procedures.
• Inspect completed contractor work before acceptance.

Continuous Improvement

• Support Lean Manufacturing and equipment reliability initiatives by: Improving preventive maintenance programs, Reducing emergency breakdowns, Increasing equipment uptime, Improving Overall Equipment Effectiveness (OEE), Participating in Root Cause Analysis investigations, Supporting CAPA activities, Assisting Engineering with equipment upgrades and new equipment installations, Developing standardized maintenance procedures, Identifying opportunities to reduce maintenance costs while improving equipment reliability.

Safety and Regulatory Compliance

• Ensure compliance with: OSHA regulations, Lockout/Tagout (LOTO), Good Manufacturing Practices (GMP), Hazard Communication, Electrical Safety, Machine Guarding requirements, Company Environmental, Health, and Safety policies.
• Verify all maintenance work is completed safely before equipment is returned to production. Immediately report unsafe conditions and initiate corrective actions when necessary.

Training and Leadership

• Train and mentor Maintenance Technicians on equipment maintenance, troubleshooting, and safe work practices.
• Provide coaching and technical guidance.
• Assist with technician competency evaluations.
• Review employee timecards in the HRIS system.
• Support employee development through ongoing technical training.

Key Performance Indicators (KPIs)

• Performance will be evaluated based on: Equipment uptime, Overall Equipment Effectiveness (OEE), Mean Time Between Failures (MTBF), Mean Time to Repair (MTTR), Preventive Maintenance compliance, Work Order completion rate, Emergency maintenance reduction, Equipment reliability improvements, Maintenance cost control, Safety performance, Contractor performance, Documentation accuracy.

Required Knowledge, Skills, and Abilities

Technical Skills

• Advanced knowledge of industrial mechanical, electrical, pneumatic, and hydraulic systems.
• Experience troubleshooting automated manufacturing equipment.
• Knowledge of motors, drives, sensors, PLC-controlled equipment, and machine controls.
• Ability to read electrical schematics, mechanical drawings, and technical manuals.
• Proficiency using precision measuring tools and diagnostic equipment.
• Experience operating CMMS software.

Leadership Skills

• Ability to lead maintenance teams and coordinate multiple repair priorities.
• Strong organizational and delegation skills.
• Excellent decision-making abilities.
• Ability to coach and mentor technicians.

Problem Solving

• Advanced troubleshooting skills.
• Root Cause Analysis (RCA).
• Failure analysis.
• Continuous Improvement mindset.

Communication

• Excellent verbal and written communication skills.
• Ability to communicate effectively with Production, Engineering, Quality, Purchasing, contractors, and management.

Minimum Qualifications

• High School Diploma or GED required.
• Associate degree or technical certification in Industrial Maintenance, Mechatronics, Electrical Technology, or a related field preferred.
• Minimum five (5) years of industrial maintenance experience in a manufacturing environment.
• Minimum two (2) years of leadership or lead maintenance experience preferred.
• Experience with automated packaging or filling equipment.
• Experience using a Computerized Maintenance Management System (CMMS).
• Working knowledge of OSHA regulations, Lockout/Tagout (LOTO), and Good Manufacturing Practices (GMP).

Preferred Certifications

• Industrial Electrical Certification
• PLC Troubleshooting Training
• OSHA 30-Hour General Industry
• Lean Manufacturing