What are the responsibilities and job description for the Maintenance Manager position at Genpak LLC?
ROLE:
The Maintenance Manager is responsible for overseeing the maintenance requirements of production, facility, and utilities for a 24/7 manufacturing environment. Design, implement and manage programs for effective maintenance operations.
Responsibilities are to be completed with consideration of safety, cost, efficiency, timeliness, and production of a quality product within specifications. This is a highly collaborative position requiring strong organizational, follow up and communication skills.
ESSENTIAL DUTIES AND RESPONSIBILITIES
- Establish plans which support company maintenance and performance objectives and communicate these effectively to the plant teams and all levels of employees.
- Provide technical guidance and expertise to aid in the accomplishment of objectives and develop a knowledgeable and efficient maintenance team.
- Identify and lead root cause analysis of maintenance failures.
- Support problem resolution and decision-making.
- Manage reliability requirements as determined by the Corporate Reliability Manager.
- Establish systems to collect data, analyze productivity and set targets to meet department goals
- Changeover targets
- Overall Equipment Efficiency
- Establish and meet corporate key performance indicators
- Assist with preparation and management of maintenance budgets to meet set objectives.
- Implement and utilize visual and structured communications through a well implemented and sustained Tier process.
- Establish an environment that prioritizes the response to outages and the restoration of equipment functionality.
- Ensure utilization of Computerized Maintenance Management System (CMMS), LEAN tools and computer applications to:
- Improve Operational Equipment Efficiencies (OEE) percentages and reduce equipment downtime.
- Track key performance indicators on an ongoing basis.
- Identify and communicate issues to plant management.
- Implement appropriate corrective actions to deliver departmental results.
- Identify predictive maintenance opportunities and ensure timely completion of changeovers, set-up, and preventative maintenance requirements
- Maintain accurate records of maintenance operations
- Support management and prioritization of work orders
- Use a comprehensive and methodical project management approach to ensure successful implementation from inception through to completion.
- Prepare and present timelines and budgetary requirements.
- Manage internal and external participants for successful completion of objectives, through project status meetings focused on on-time and on-budget delivery.
- Work directly with Original Equipment Manufacturers (OEMs)
- Maintain Operations team involvement with and knowledge of the project through effective communications including status and debriefing meetings.
- Manage and develop a highly skilled maintenance staff that is process driven and excellence motivated.
- Hire and train a team of maintenance employees to conduct a full range of responsibilities at the manufacturing site.
- Identify roles and responsibilities with the maintenance department.
- Coach and develop existing employees within a pay-for-skills environment.
- Identify, implement, and manage effective training programs and procedures in the maintenance area and ensure training requirements are met.
- Develop employees for next level opportunities to ensure your and their progression within the organization.
- Conduct timely skills evaluations.
- Translate plant goals into functional and individual goals.
- Facility maintenance and monitoring that is focused on providing a safe and work friendly environment at an acceptable cost.
- Maintain improvement year over year in kWh per finished good pounds.
- Through the application of LEAN tools such as 5S and Gemba walks, supervise the activities of the building/utility/mech upkeep ensuring personnel maintain a clean and orderly facility.
- Ensure that employee work and non-work areas are structurally sound, functional, safe, and environmentally compliant
- Manage and monitor the completion of day-to-day maintenance responsibilities.
- Perform daily and weekly inspection of facility to ensure smooth Operations.
- Demonstrate a year over year improvement on Maintenance Scorecard as evaluated during Operations Review process.
- Monitor costs and expenses to meet budget goals and ensure optimal cost effectiveness.
- Promotes knowledge sharing across the facilities to fully leverage innovation and process improvements.
- Actively participate in and support plant flex scheduling program.
TECHNICAL COMPETENCIES:
Project Management:
- Ability to identify, oversee, coordinate and/or support continuous improvement projects from conception through to implementation
- Yearly Capex planning and management.
Interpersonal/Communication:
- Demonstrates the servant leadership values of valuing people, humility, listening, trust and caring toward the employees under their stewardship.
- Demonstrates a high level of responsiveness to employee concerns and ideas for improvement.
- Ability to participate and/or foster interdepartmental communication and teamwork.
- Ability to prioritize multi-task duties without loss of efficiency or composure.
- Effective written and verbal communication and the ability to disseminate information in a timely and diplomatic manner.
- Ability to work under pressure, meet scheduled deadlines, respond to emergency situations without loss of efficiency or composure.
- Communicate regularly and pro-actively with upper management regarding problems or issues impacting equipment maintenance.
- Ability to establish and build relationships with internal/external customers.
- Ability to utilize professional negotiations skills and training.
Technical Knowledge:
- Demonstrates familiarity with:
- precision maintenance tooling to include precision laser alignment, torque wrenches
- thermoforming and extrusion equipment
- industrial support equipment
- Demonstrates fundamental understanding of polymer processing to include extrusion and thermoforming.
- Ensure asset reliability through TPM, Lean, Autonomous Maintenance, Root Cause Analysis, and other reliability tools.
- Ability to analyze and apply knowledge of machine/equipment capabilities to maximize production schedules.
- Demonstrates a fundamental understanding of standard manufacturing business processes.
Efficiency:
- Demonstrate ability to initiate and perform root cause analysis and implement corrective action to drive improvement.
- Ability to meet or exceed performance standards and continuously improve upon them.
Quality:
- Ensure compliance with GMP, SPC and SQF requirements within the department.
Compliance & Regulatory:
- Maintain required records and documentation, as related to safety training, NFPA compliance, environmental regulations, preventative maintenance for internal/external audit requirements including EPA, OSHA, SPC, GMP, SQF and customer specific (Panda Express, Yum).
Safety:
- Demonstrated ability to comply with all Company policies and procedures and to uphold, support and exemplify the safety programs and standards.
- Demonstrated understanding of the key components that comprise an effective plant wide safety program along with the ability to lead, develop and drive world class safety performance.
- Ensure department is compliant with company, OSHA, EPA, local, state, and federal and standards.
DUCATION & EXPERIENCE:
- Minimum of 5 years of experience in a managerial or supervisory position.
- Education or a degree in a relevant field a plus.
- Knowledge of the Plastics Industry processes and equipment, specifically extrusion and thermoforming.
- Knowledge of raw material and production supplies utilized in the production of finished goods.
- Knowledge of MS Office and familiarity with database applications.
- Basic understanding of plastic physical properties and behaviors
ADA – ESSENTIAL FUNCTIONS:
Must be able to:
- Work an 8-hour shift with overtime as required.
- Stand and/or walk constantly, sit frequently
- Speak and hear constantly
- Use of fingers, hands, and arms constantly
- Additional information can be found on the job specific Job Profile Medical Assessment
Req Benefits: Genpak offers a comprehensive benefits package to all team members which includes but is not limited to: * Comprehensive medical, dental and vision * Paid Vacation Time * 11 Paid Holidays * 401k with a generous company match * Wellness programs * Tuition Reimbursement * Daily Pay Access
