General Summary:The Maintenance Manager is responsible for planning, directing, and coordinating all maintenance activities within the plant to ensure safe, efficient, and reliable operation of equipment and facilities. This role focuses on maximizing equipment uptime, minimizing production disruptions, and maintaining high standards of safety and compliance. The Maintenance Manager oversees preventive and predictive maintenance programs for critical equipment around the plant. This position plays a key role in driving continuous improvement initiatives, ensuring regulatory compliance, and maintaining a safe working environment.
Principle Duties and Responsibilities:- Direct, plan, and coordinate all maintenance activities to support safe and efficient foundry operations.
- Ensure maximum uptime and reliability of critical foundry equipment including melting furnaces, molding lines, core machines, sand systems, shakeout equipment, conveyors, grinders, dust collection systems, and material handling equipment.
- Develop and execute predictive, preventive, and corrective maintenance programs to improve equipment reliability and reduce unplanned downtime.
- Partner with Production, Engineering, Quality, and Safety teams to identify and eliminate chronic equipment issues impacting productivity and quality.
- Lead root cause analysis investigations for major equipment failures and implements corrective actions.
- Manage maintenance support for plant shutdowns, outages, capital projects, equipment installations, and commissioning activities.
- Oversee contractor activities to ensure compliance with company safety standards and project requirements.
- Monitor and improve maintenance KPIs including downtime, MTBF (Mean Time Between Failures), PM completion rates, maintenance costs, and equipment availability.
- Ensure compliance with environmental, safety, and regulatory requirements related to foundry operations.
- Develop and maintain spare parts strategies for critical foundry equipment to minimize production interruptions.
- Support continuous improvement initiatives including Lean Manufacturing, TPM (Total Productive Maintenance), and reliability-centered maintenance practices.
- Train, coach, and develop maintenance supervisors and technicians to enhance technical capabilities and leadership skills.
- Support energy management initiatives related to compressed air, natural gas, electrical systems, melting operations, and utility consumption.
Knowledge, Skill, and Ability Requirements:- Strong knowledge of foundry processes including melting, molding, core making, pouring, shakeout, finishing, and material handling systems.
- Working knowledge of electrical, hydraulic, pneumatic, mechanical, and PLC-controlled manufacturing equipment.
- Experience troubleshooting induction furnaces, dust collection systems, air compressors, cooling systems, conveyors, robotics, and automated production equipment.
- Knowledge of predictive maintenance technologies including vibration analysis, thermography, oil analysis, and condition monitoring.
- Understanding of OSHA requirements, lockout/tagout procedures, machine guarding, and industrial safety practices.
- Experience with CMMS systems and maintenance planning software.
- Ability to analyze maintenance data and develop strategies to improve equipment performance and reliability.
Working Conditions- The Maintenance Manager will reside in the office and on the production floor. Must be able to adhere to conditions of the plant.
Physical Requirements- Must be able to remain in a stationary position 50% and on their feet 50% on the production floor.
- Must be able to move about inside the office and in the plant.
- This position will operate a computer and other machinery in the plant.
- Must be able to frequently communicate with employees and other individuals in person and telephone.
Education and Experience Requirements:- Experience in foundry, metal casting, heavy manufacturing, steel, aluminum, iron, or similar industrial environment strongly preferred.
- Minimum 10 years of progressive maintenance leadership experience in manufacturing or foundry setting.
- Demonstrated experience managing maintenance budgets, capital projects, and reliability improvement initiatives.
- Experience supervising multi-craft maintenance teams including electricians, millwrights, mechanics, and controls technicians.
- Experience with automated manufacturing systems, robotics, PLCs, and industrial controls preferred.
Nothing in this job description restricts management's right to assign or reassign duties and responsibilities to this job at any time. 
