Manager Facilities Manager - Paint

Career Area:

Manufacturing

Job Description:

Your Work Shapes the World at Caterpillar Inc.

When you join Caterpillar, you're joining a global team who cares not just about the work we do – but also about each other. We are the makers, problem solvers, and future world builders who are creating stronger, more sustainable communities. We don't just talk about progress and innovation here – we make it happen, with our customers, where we work and live. Together, we are building a better world, so we can all enjoy living in it.

Role Definition

The Paint Maintenance Manager is responsible for leading all maintenance, reliability, robotics, automation, and utility activities within the paint shop. The role ensures maximum equipment availability, optimal paint quality, environmental compliance, and safe operations across pretreatment, e-coat, powder coating, liquid paint, and curing processes. The position requires extensive experience with robotic paint application systems and automated paint shop technologies.

Key Responsibilities

Maintenance & Reliability Leadership

Lead all mechanical, electrical, robotics, controls, and utility maintenance activities in the paint shop.

Develop and implement preventive, predictive, and reliability-centered maintenance programs.

Establish maintenance KPIs and drive continuous improvement initiatives.

Ensure paint shop equipment availability exceeds business targets.

Minimize downtime through proactive maintenance planning and root cause elimination.

Robotics & Automation Management

Lead maintenance and troubleshooting of robotic paint systems including:

ABB Paint Robots

KUKA Paint Robots

Ensure reliable operation of:

Robot applicators and atomizers

Robot controllers and teach pendants

Paint dosing and color change systems

Vision systems and process monitoring equipment

Servo motors, drives, and robotic axes

Manage robot programming backup, restoration, and software upgrades.

Coordinate robot calibration, TCP validation, and path optimization.

Support robotic cycle-time improvements and paint transfer efficiency projects.

Paint Shop Equipment Maintenance

Responsible for maintenance of:

Pretreatment systems

Phosphating systems

E-Coat systems

Powder coating equipment

Paint circulation systems

Spray booths

Paint kitchen systems

Ovens and curing equipment

Conveyors and skids

Lift systems and hoists

Air handling units (AHU)

Exhaust and filtration systems

Pumps, valves, piping systems

Compressed air systems

Water treatment plants (WTP)

Effluent treatment plants (ETP)

Fire protection systems

Controls & Electrical Systems

Maintain PLC, SCADA, and HMI systems.

Troubleshoot automated paint process controls.

Ensure integrity of industrial networks and communication systems.

Support Industry 4.0 initiatives and smart manufacturing projects.

Manage system backups and cybersecurity compliance for automation equipment.

Reliability & Continuous Improvement

Implement TPM and Reliability-Centered Maintenance (RCM).

Conduct Root Cause Analysis (RCA) and Failure Mode Effect Analysis (FMEA).

Utilize predictive maintenance technologies:

Vibration Analysis

Thermography

Ultrasound Inspection

Oil Analysis

Improve Overall Equipment Effectiveness (OEE).

Lead maintenance cost reduction initiatives.

Safety, Environmental & Regulatory Compliance

Ensure compliance with all EHS regulations.

Maintain safe operation of paint systems involving flammable materials.

Implement Lockout/Tagout (LOTO) procedures.

Ensure compliance with VOC emission standards and environmental regulations.

Conduct safety audits, risk assessments, and hazard analyses.

Support ISO 9001, ISO 14001, and ISO 45001 compliance requirements.

Capital Projects & Plant Expansion

Lead installation and commissioning of paint robots and automation systems.

Support greenfield and brownfield paint shop projects.

Manage equipment upgrades and modernization programs.

Coordinate with OEMs, integrators, suppliers, and contractors.

Ensure maintainability requirements are incorporated into new equipment specifications.

Budget & Asset Management

Prepare and manage annual maintenance budgets.

Control maintenance costs while maintaining reliability targets.

Optimize spare parts inventory, including critical robot spare components.

Manage vendor contracts and service agreements.

Develop long-term asset replacement strategies.

Team Leadership & Development

Lead a multidisciplinary team of:

Mechanical Engineers

Electrical Engineers

Automation Engineers

Robotics Engineers

Supervisors and Technicians

Develop technical training programs focused on robotics and automation.

Build succession plans and technical competency matrices.

Drive a high-performance, accountable maintenance culture.

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Educational Qualifications

Required

Bachelor's Degree in Mechanical Engineering, Electrical Engineering, Mechatronics, Automation Engineering, or Industrial Engineering.

Preferred

Certifications in:

TPM

Reliability Engineering

Six Sigma Green/Black Belt

Project Management

ABB or KUKA Robot Programming & Maintenance

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Experience

Required

5-15 years of maintenance experience in automotive, off-highway, engine, genset, or industrial manufacturing.

Minimum 5 years in a maintenance leadership role.

Minimum 5 years of hands-on experience with robotic paint application systems.

Preferred

Experience in automotive OEM paint shops.

Greenfield facility setup and commissioning experience.

Experience with Industry 4.0 and digital manufacturing systems.

Exposure to automated paint lines with 20+ robots.

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Technical Skills

Robot Programming & Maintenance (ABB, KUKA)

Paint Process Technology

PLC (Siemens,)

SCADA & HMI Systems

Servo Drives & Motion Control