Job Summary
Maintenance Manager is responsible for overseeing all maintenance operations to ensure maximum equipment reliability, safety, and efficiency in an aluminum molten metal plant. This includes managing preventive and predictive maintenance programs, leading maintenance teams, planning and executing shutdowns, ensuring compliance with safety and environmental regulations, and supporting continuous improvement initiatives. This role ensures departmental practices align with company policies and support the operational and cultural goals of the plant while promoting a safe, inclusive, and productive work environment.
Essential Duties & Responsibilities
Leadership & Management
- Lead, mentor, and develop maintenance supervisors, technicians, and support staff.
- Establish clear maintenance priorities aligned with production goals and safety standards.
- Develop and manage department budgets, including labor, materials, and capital expenditures.
- Collaborate with operations team to improve plant performance.
Project Management:
- Plan, design, and manage capital improvement projects to support plant operations, to include start up and commissioning.
- Collaborate with cross-functional teams on new equipment installations and upgrades.
- Conduct root cause analysis of equipment failures and implement engineering solutions.
- Maintain plant drawings, equipment manuals, and engineering documentation.
Equipment & Facility Maintenance
- Oversee the maintenance of furnaces, casting equipment, molten metal handling systems, conveyors, cranes, HVAC, and other critical plant systems.
- Implement and manage preventive and predictive maintenance programs to reduce downtime.
- Ensure timely and effective troubleshooting and repair of equipment failures.
- Plan and coordinate maintenance shutdowns and major repairs.
Safety & Compliance
- Enforce strict adherence to safety policies and procedures (e.g., lockout/tagout, confined space, hot work).
- Ensure maintenance activities comply with OSHA, EPA, and other regulatory standards.
- Promote a culture of safety and continuous improvement throughout the maintenance team.
Inventory & Procurement
- Oversee spare parts inventory, critical spares, and consumables to support uninterrupted operations.
- Work closely with procurement to source parts and services cost-effectively.
Continuous Improvement & Reliability
- Analyze equipment performance and failure data to identify root causes and implement corrective actions.
- Lead reliability-centered maintenance (RCM) and continuous improvement initiatives.
- Support implementation of new technologies and equipment upgrades to enhance efficiency and safety.
Documentation & Reporting
- Maintain accurate maintenance records, work orders, equipment histories, and compliance documentation.
- Provide regular reports on maintenance performance metrics.
- Other Duties as assigned.
Qualifications
- Bachelor's degree in Mechanical Engineering, Electrical Engineering, Industrial Maintenance, or a related field.
- Equivalent experience in lieu of a degree may be considered.
- 7+ years of maintenance experience in heavy industrial environments, preferably in aluminum or metals manufacturing.
- Minimum 5+ years of supervisory or managerial experience in maintenance.
- Strong background in molten metal processes, furnace maintenance, and heavy equipment.
Skills & Competencies
- Deep understanding of maintenance best practices, preventive/predictive maintenance, and reliability engineering.
- Knowledge of molten metal safety and high-temperature process equipment.
- Excellent leadership, communication, and team-building skills.
- Proficiency in Microsoft Office as well as in CMMS (Computerized Maintenance Management Systems).
- Strong interpersonal and communication skills with the ability to build relationships across all levels of the organization. Ability to communicate effectively both one-on-one and to present information in a group setting.
- Strong analytical and problem-solving skills.
- Facility start-up experience would be a plus.
Certifications (Preferred)
- Certified Maintenance & Reliability Professional (CMRP) or similar.
- OSHA safety certifications.
Physical Requirements
- Ability to wear required PPE (personal protective equipment), including heat-resistant gear.
- Capability to perform inspections in confined spaces and elevated areas.
- Must be able to work extended hours and respond to emergencies as needed.
- Requires frequent physical activity, including walking, climbing, lifting, and standing for long periods. Must be able physically access all areas of the plant work areas.
- Must have normal or corrected vision and must have depth perception and the ability to distinguish color. Must have normal or corrected hearing.
- Must have a valid driver's license and be able to travel locally to support business needs.
Working Environment
- Primarily plant environment with exposure to high heat, molten metal, heavy machinery, and noise.
