Maintenance Manager, General Assembly

Job Description

Job Description

Maintenance Manager, General Assembly

Location: Warsaw, IN

Position Summary

We are seeking an experienced and hands-on Maintenance Manager to lead all maintenance activities within a high-volume General Assembly manufacturing environment. This role is responsible for overseeing equipment reliability, robotic systems, conveyance systems, facility infrastructure, breakdown management, preventive maintenance programs, and capital improvement projects.

The Maintenance Manager will provide leadership to a skilled maintenance team while partnering closely with Production, Engineering, and Plant Leadership to maximize equipment uptime, improve operational efficiency, and support a world-class safety culture. This position plays a key role in driving continuous improvement, equipment reliability, and long-term asset performance.

Key Responsibilities

• Lead, coach, and develop a team of maintenance technicians and skilled trades personnel.
• Establish and enforce safe work practices, including Lockout/Tagout (LOTO), PPE requirements, and standard operating procedures.
• Manage preventive, predictive, and corrective maintenance programs to improve equipment reliability and reduce downtime.
• Troubleshoot and oversee repairs involving mechanical, hydraulic, pneumatic, electrical, PLC, robotic, and vision systems.
• Collaborate with Production and Engineering teams to identify root causes of equipment failures and implement corrective actions.
• Lead breakdown response efforts and ensure timely restoration of production equipment.
• Manage maintenance planning, scheduling, and execution of equipment repairs and upgrades.
• Coordinate contractor and vendor activities while ensuring compliance with safety, quality, and performance standards.
• Oversee installation, rigging, alignment, rebuilding, and commissioning of production equipment.
• Manage spare parts inventory, critical spare strategies, and maintenance cost controls.
• Review and interpret blueprints, schematics, technical drawings, and equipment manuals.
• Maintain accurate maintenance documentation, including work orders, preventive maintenance records, and downtime tracking.
• Monitor and report key maintenance metrics such as MTBF, MTTR, and maintenance backlog.
• Support capital projects, equipment upgrades, and facility improvement initiatives.
• Promote housekeeping standards, 5S programs, and continuous improvement initiatives throughout the facility.
• Provide recommendations on long-term equipment reliability strategies, facility improvements, and capital investments.

Required Qualifications

Experience & Education

• Bachelor's degree in Engineering, Manufacturing, Industrial Technology, or a related field preferred.
• Minimum of 10 years of industrial maintenance experience in a manufacturing environment.
• At least 4 years of leadership, supervisory, or maintenance management experience.
• Experience supporting automated manufacturing, assembly operations, or similar production environments.

Technical Skills

• Strong hands-on knowledge of conveyors, bearings, shafts, seals, hydraulics, pneumatics, and mechanical systems.
• Experience with welding, fabrication, machining, rigging, cranes, hoists, and industrial lifting equipment.
• Working knowledge of PLCs, industrial electrical systems, robotics, and automation controls.
• Ability to read and interpret blueprints, electrical schematics, technical manuals, and engineering drawings.
• Experience utilizing computerized maintenance management systems (CMMS).

Leadership Skills

• Demonstrated ability to lead, coach, develop, and motivate multi-skilled maintenance teams.
• Strong communication, organizational, and problem-solving skills.
• Proven ability to manage priorities in a fast-paced manufacturing environment.

Continuous Improvement

• Experience implementing TPM, Lean Manufacturing, Kaizen, and Continuous Improvement initiatives.
• Track record of improving maintenance performance metrics, equipment reliability, and overall operational effectiveness.

Preferred Qualifications

• Professional certifications related to maintenance, reliability, safety, leadership, or continuous improvement.
• Six Sigma certification or equivalent process improvement training.
• Forklift and aerial lift certifications, or ability to obtain certification.
• Experience managing maintenance budgets, vendor relationships, and capital improvement projects.

Additional Requirements

• Ability to support off-shift operations, weekends, and overtime as business needs require.
• Proficiency with Microsoft Office applications and maintenance management software.
• Strong commitment to safety, operational excellence, and team development.

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