Maintenance and Facilities Manager

Description

Responsible for managing all maintenance functions and resources to ensure safe, reliable, and cost efficient operation of plant assets, manufacturing processes, and site infrastructure. Drive asset reliability, mechanical integrity and improvement initiatives to support business growth objectives.

Maintenance Leadership & Execution

• •Execute a comprehensive maintenance strategy including predictive, preventive, and corrective maintenance programs for highly complex polyurethane process systems which include tanks, reactors, pressure vessels, mixers, pumps, ovens, utilities, controls, and various support systems.
• •Build, lead and develop a high preforming maintenance operation with 24/7 coverage capabilities. Ensure rapid and effective response to equipment breakdowns and process interruptions.
• •Hire, train, supervise and develop maintenance technicians across mechanical, electrical, instrumentation, welding and pipefitting disciplines.
• •Establish clear roles, accountability and performance expectations for the maintenance team. Conduct team member performance evaluations throughout the year and provide feedback on continued growth and improved performance. Set up outside technical skills training for technicians for ongoing professional development.

Planning, Asset Reliability and Mechanical Integrity

• •Build a reliability centered maintenance program for all critical assets. Responsible for the CMMS system, asset history, and work order management. Lead failure and root cause analysis for high impact equipment issues.
• •Establish and maintain a mechanical integrity program for all tanks, pressure vessels, piping systems compliant with API, ASME and internal standards.
• •Track maintenance KPIs including safety performance, unplanned downtime and reduced failure rates, program compliance and completion rate, work order completion rates.
• •Work closely with maintenance techs, production, engineering and EHS to prioritize work orders and all maintenance activities to increase proactive versus reactive maintenance. Optimize and focus resources on reducing process and equipment issues in all production areas. Ensure smooth plant operations to eliminate production downtime.
• •Own spare parts strategy which includes critical spares inventory, inventory stocking levels and reorder points, warehouse organization and optimized accessibility of spare parts.
• •Monitor and control maintenance spending, including ongoing vendor price benchmarking.
• •Support CAPEX projects as needed from conceptual design through installation and startup to drive operational improvements and capacity expansion. Support commissioning and startup of new equipment and systems.
• •Optimize the use of outside contractors versus internal resources.
• •Manage a tight budget and control maintenance labor, parts and contractor spend.

Operational Excellence & Regulatory Compliance

• •Ensure compliance with OSHA, EPA and all applicable safety, environmental, and regulatory standards.
• •Maintain all maintenance procedures and other necessary documentation.
• •Integrate safety into all maintenance activities including LOTO, confined space work, hot work and contractor management. Drive a strong safety culture with zero tolerance for unsafe work practices.
• •Lead and assist with behavioral based and periodic Plant safety audits.
• •Lead 5S improvements throughout maintenance, satellite maintenance shops, spare parts storage areas and support global plant 5S activities.
• •Execution of annual SMART goals to drive overall business improvements in safety, quality, cost and delivery performance.

Experience & Technical Knowledge

• •Facilities or project engineering experience
• •Experience working with contractors in various trades
• •Solid understanding of electrical and mechanical systems
• •Plant utility and facilities equipment, including:
• •Pressure vessels, high-pressure steam boilers, and thermal oil heating systems
• •Chilled water systems, cooling towers, and pumping systems
• •Electrical distribution, HVAC systems, motors, controls, MCCs, and compressed air

Requirements

• •Strong technical knowledge of industrial mechanical, electrical, and control systems in chemical manufacturing
• •Minimum 7–10 years maintenance leadership experience in process manufacturing (urethane, coatings, or specialty chemicals preferred)
• •Bachelor's degree in mechanical, Electrical, or Industrial Engineering or equivalent relevant experience
• •Excellent communication skills
• •Proficient computer skills with spread sheets, databases and word processing
• •CMMS (e.g., Fiix, eMaint, SAP) expertise
• •Proven track record of building a maintenance reliability culture
• •Strong problem solving, planning, and cross-functional collaboration skills