The Maintenance Leader is responsible for assuring the reliability and uptime of all plant electrical, utility and mechanical systems by developing, leading, and executing best-in-class maintenance strategies. This is accomplished by leading the maintenance department and setting strong objectives to optimize PM’s on all critical pieces of equipment, training craftsmen on how to optimize uptime and performance of this equipment, life cycle asset management of all facility systems, leading the site predictive maintenance program, continuously improving the Reliability Work Process, and partnering with process area owners to ensure equipment reliability.
This position reports to the Plant Leader of the facility.
1. Live the Safety stand; adhere to the safety responsibilities
- Demonstrate a commitment to employee health and safety, particularly through a commitment to zero injuries, awareness of hazards, and a strong understanding of legislative requirements in all aspects of the operation.
- Leads comprehensive and strict JHA executions for safe maintenance works in accordance to OC standards
- Partners with cross-functional team to implement safety programs (Lock, Tag and Try, C6, etc.) at the plant
- Prioritizes and executes EHS hazards elimination in daily RWP (ReliabilityWork Process) management
- Safety Metrics – First Aids, Near Misses, SAFE, Critical 6
- Hazard identification and control/resolution
- Assist in reducing Risk Assessment Score
- ZERO injuries
2. Develop, Lead, and Execute Plant Maintenance Strategy
- Develop a Plant maintenance strategy and define critical outcomes, consistent with business strategy and operation plans and lead its execution
- Prepares capital budget forecasts, cost estimates and operational plan for plant improvements
- Effectively manages all capital projects/installations and delivers committed results in a timely and cost effective manner
- Maintains budget (labor, contractor, repair & replacement) and inventory of spare parts in a fiscally responsible manner
- Optimizes energy balance and utility usage and deploys plant-wide energy savings plan
- Develops and monitors measures (KPI’s) for maintenance of equipment tosupport business objectives of the plant
- OEE (Overall Equipment Effectiveness)
- MTBF and MTTR (Mean Time Between Failure and Mean Time To Repair)
- Cost Controls
3. Deliver equipment reliability and uptime to Operations
- Keep Leadership Team fully apprised of investments and/or resources required to ensure all electrical, utility and mechanical equipment/systems are operating in a fully restored condition.
- Own Utility support: chillers, air compressors, air driers, HVAC systems, cooling towers, process water, water scrubber systems, water treatement systems, and electricaldistribution systems.
- Work with Predictive Maintenance assets (internal and external) to eliminate failures that can be predicted utilizing predictive test equipment: such as, vibration data analysis, infrared thermography, oil analysis, and ultrasonic leak detection equipment.
- Train PM electro-mechanics and AM operators on key inspection, cleaning, and lubrication practices required on all critical utility and mechanical equipment.
- Designs and implements effective Preventive Maintenance Master and Implementation plans, to sustain and enhance plant facility reliability; Ensures that the PM plan reflects the equipment and system changeover, aging and modifications
- Reviews the daily Reliability Work Process (RWP) process to prioritize the operations and maintenance tasks and ensure timely and efficient support to other functions
- Work with different vendors to ensure our purchased equipment, storeroom parts, water treatment systems, and contracted labor contracts places our facility in the most cost-competitive situation.
- Controls/reduces operating cost – identify opportunities to enhance efficiencies, streamline processes and leverage resources lowering cost
- Leads focus improvement, planned maintenance, and quality maintenance initiatives as well as the relevant training programs
- Successfully engages employees across the organization to participate and contribute to TPM
- Actively support a “ZERO defect” culture within the crafts organization and the plant as a whole.
- Develops engineering solutions to repetitive failures and all other problems that adversely affect plant operations, quality, and/or safety goal by usage of methodical problem solving techniques.
- % Completion of A and B critical equipment PM’s
- Operational and Piece Job Efficiencies (OE and PJE)
- Departmental Financial Forecasts/Adherence
- Working Capital Reductions
- Cost/KG improvement driven through TPM and improved maintenance systems/processes
4. Ensure our crafts organization is well-trained and working efficiently
- Ensures maintenance employees are well trained and current on any required certifications to perform the full scope of their job expectations
- Ensure proper Labor Model of all craftspeople
- Effectively staffs the team by leveraging the appropriate mix of internal and external talent to satisfy both near-term performance and long-term succession needs
- Support maintenance supervision to ensure our craftsmen are working efficiently and being effective on all planned and reactive work
- Establishes clear and measurable performance expectations and holds team members accountable for delivering the goals
- Regularly evaluates the strengths and development opportunities of the team, as well as invests in the growth and development of team members to achieve sustained success
- Advancement of training plans toward qualification and specialist levels
- Progress on training plan and % reduction of skills gap
- Succession Plans
- Employee engagement and development
5. Leading across the plant/division
- Drives alignment between plant departments
- Shares best practices across plants, challenges thinking and provides candid and respectful feedback; sets an example for the organization of how teamwork and partnerships should look
- Is seen as a great leader across the plant, driving engagement and supporting cross-functional projects and teams
- Is seen as a leader amongst peers across sister plants
- Assists the plant leader with other duties as required
- Communicate expectations around continuous improvement and TPM with all team members
- Provide ongoing operations statistical updates to lead team and employees
- Communicate financial and statistical data in a manner that the employees can understand and use the information to improve operations. Utilize 5S and TPM methodologies and tools
- Ensure coordinated communication and direction across all shifts and through leadership
- Act as an agent for positive change, continually raising the bar with the objective of attaining and sustaining world class manufacturing performance as defined by CSB Manufacturing Leadership
- 4-Year engineering degree
- 5-7 years manufacturing experience in an engineering and maintenance leadership role
- Understanding of planned maintenance techniques (RWP, SAP, etc.)
- Microsoft Office capability
- Openness to relocation to areas around the world including to OC World Headquarters, located in Toledo, Ohio, for growth opportunities in the future.
Knowledge, Skills and Abilities:
- Preffered Master Degree in Engineering or equivalent experience
- Mechanical and electrical background, knowledge of industrial utilities systems
- Understanding and knowledge of mechanical drive systems, pneumatic systems, and hydraulic systems
- Demonstrated leadership in sustaining and improving plant safety
- In-depth knowledge and understanding of the work processes and procedures on one or more production lines; technical acumen
- Knowledge and application of operational excellence tools.
- Demonstrated success utilizing continuous improvement tools
- Ability to make decisions quickly and adapt to unplanned situations
- Financial acumen, knowing key drivers to business success
- Ability to build strong team alignment and communication (achieve results fast both individually and through teams)
- Teach, coach and guide for results
- Local language + Fluent English
- Knowledge of plant policies and procedures
Abilities and Personal Characteristics:
- Strong analytical skills
- Strong interpersonal and leadership skills
- Effective communication
- Results Oriented
- Tolerance for stress and resilience
- Leverages own and others’ Strengths
- Ability to organize and lead multi-functional teams to achieve plant objectives
- Ability to prioritize and adapt to a rapid changing environment while balancing multiple responsiblities