POSITION PURPOSE
The Senior Manager, Maintenance is responsible for leading the site Maintenance organization across all shifts. This role provides leadership for maintenance execution discipline, preventive maintenance performance, CMMS adoption, supervisor accountability, shift-to-shift continuity, and equipment reliability improvement.
The role is accountable for ensuring Maintenance remains focused on equipment reliability, technical health, PM execution, repeat failure elimination, and rapid response to production-critical issues. The Senior Manager, Maintenance will drive a culture of accountability, communication, standard work, and data-driven decision-making across the Maintenance team.
This position plays a key role in sustaining a system-driven, three-shift reliability organization and ensuring daily maintenance behaviors align with the site ownership model.
ESSENTIAL FUNCTIONS AND BASIC DUTIES
Maintenance Execution Leadership
- Lead Maintenance execution across all shifts to improve reliability, reduce unplanned downtime, and strengthen response discipline.
- Establish clear expectations for Process and Packaging Maintenance Manager/Supervisors, mechanics, lead mechanics, planner, and support roles.
- Drive daily execution discipline through structured shift reporting, escalation adherence, issue tracking, and follow-up.
- Ensure Maintenance resources remain focused on production-critical equipment reliability, PM execution, technical troubleshooting, and repeat failure elimination.
- Lead daily and weekly Maintenance reviews focused on downtime, break-ins, PM adherence, schedule completion, repeat issues, and open action closure.
- Build consistency across all three shifts by strengthening communication, handoffs, work standards, and leadership routines.
CMMS Ownership and Work Management Discipline
- Own site Maintenance CMMS adoption, data accuracy, and long-term sustainment.
- Establish expectations for work order creation, prioritization, planning, scheduling, execution, closeout, and documentation.
- Drive accurate asset history, failure coding, labor reporting, parts usage, and completion notes.
- Partner with the Planner/Scheduler to improve weekly and monthly maintenance planning, labor loading, schedule compliance, and PM visibility.
- Ensure CMMS data is used to identify trends, repeat failures, PM effectiveness gaps, and reliability improvement opportunities.
- Lead change management for CMMS adoption across Maintenance Supervisors, technicians, production partners, and support teams.
Preventive Maintenance and Reliability Performance
- Own PM execution performance, PM schedule adherence, and continuous improvement of preventive maintenance effectiveness.
- Drive PM optimization by eliminating low-value tasks, improving task quality, and aligning PMs to actual failure modes.
- Partner with Engineering and OpEx to identify chronic downtime drivers and support corrective action plans.
- Lead Maintenance participation in RCA, repeat failure elimination, and reliability improvement routines.
- Support implementation of predictive and condition-based maintenance practices where appropriate.
- Maintain focus on equipment technical health, uptime improvement, MTTR reduction, and MTBF improvement.
Supervisor Accountability and Team Leadership
- Lead, coach, and develop Maintenance Supervisors to strengthen shift-level ownership, accountability, and communication.
- Set clear performance expectations for shift execution, response time, work quality, PM completion, schedule adherence, and escalation discipline.
- Conduct regular performance reviews, coaching discussions, and development planning for direct reports.
- Build leadership capability across the Maintenance organization by reinforcing standard work, feedback discipline, and problem-solving behaviors.
- Promote a culture of safety, urgency, teamwork, technical excellence, and accountability.
- Ensure Maintenance leaders are visible on the floor and actively engaged in daily execution, issue resolution, and associate coaching.
Maintenance Planning, Scheduling, and Resource Management
- Lead Maintenance planning and scheduling discipline to improve planned work execution and reduce reactive work.
- Ensure appropriate labor loading across shifts for PMs, planned work, changeover support, breakdown response, and improvement work.
- Review work backlog, overdue PMs, emergency work, break-ins, and planned vs. unplanned work trends.
- Partner with the Planner/Scheduler to improve schedule lock, job readiness, parts availability, and pre-kitting.
- Align resources to production priorities while protecting PM execution and reliability-critical work.
- Support hiring, onboarding, cross-training, and succession planning for Maintenance talent.
Spare Parts and Reliability Readiness
- Provide leadership oversight for spare parts strategy, inventory discipline, and maintenance readiness.
- Ensure critical spare parts are identified, stocked, maintained, and linked to high-risk assets.
- Partner with the Spare Parts Supervisor to improve inventory accuracy, stockout prevention, vendor support, and planned work readiness.
- Reinforce the expectation that spare parts management supports PM execution, breakdown readiness, and chronic downtime reduction.
Safety, Quality, and Compliance
- Ensure Maintenance work is performed in compliance with OSHA, EHS, cGMP, FDA, Quality, and internal site requirements.
- Reinforce safe work practices, lockout/tagout expectations, permit requirements, and incident-prevention behaviors.
- Ensure proper documentation of maintenance activities to support audits, investigations, validation, calibration, and equipment history.
- Partner with Quality and EHS to address maintenance-related risks, deviations, audit findings, and corrective actions.
- Maintain a high standard of housekeeping, 5S, and maintenance shop floor discipline.
Continuous Improvement and Transformation Sustainment
- Sustain the Maintenance Transformation operating model through governance, metrics, routines, and leadership behaviors.
- Drive improvement in equipment uptime, PM compliance, schedule adherence, response discipline, repeat failure elimination, and CMMS data quality.
- Use downtime data, work order data, and production feedback to identify improvement priorities.
- Partner with OpEx to support Maintenance Excellence, KPI governance, visual management, and structured problem-solving.
- Lead continuous improvement initiatives that improve reliability, reduce waste, and strengthen maintenance productivity.
- Ensure transformation gains are embedded into daily work routines and do not depend on individual firefighting.
PERFORMANCE MEASUREMENTS
- Reduction in unplanned downtime
- Improvement in PM completion and PM schedule adherence
- Improvement in planned vs. unplanned work ratio
- Reduction in repeat failures and chronic downtime events
- Improvement in MTTR and MTBF
- CMMS data accuracy and work order closeout quality
- Maintenance schedule compliance
- Break-in work tracking and reduction
- Maintenance supervisor performance and accountability
- Shift-to-shift handoff effectiveness
- Critical spare parts readiness and stockout reduction
- Safety, Quality, and audit performance
- Maintenance team capability, training, and skill matrix improvement
QUALIFICATIONS
EDUCATION/CERTIFICATION:
- Bachelor's degree in Engineering, Industrial Technology, Maintenance Management, Operations Management, or a related technical field preferred.
- Equivalent combination of education and relevant maintenance leadership experience will be considered.
- Lean, Six Sigma, TPM, SMRP, CMRP, or related reliability certification preferred.
EXPERIENCE REQUIRED:
- 10 or more years of progressive maintenance leadership experience in a high-speed manufacturing environment, including experience leading teams in a multi-shift operation.
- Experience with CMMS adoption or implementation, work management, PM execution, maintenance planning, and reliability improvement.
- Experience in FDA, cGMP, ISO, medical device, pharmaceutical, consumer products, or other regulated manufacturing environment preferred.
- Experience working in a union manufacturing environment preferred.
- Demonstrated success improving maintenance execution discipline, downtime performance, PM compliance, and team accountability.
REQUIRED KNOWLEDGE:
- Maintenance execution systems, preventive maintenance programs, predictive maintenance, work order management, and reliability fundamentals.
- CMMS work processes including asset hierarchy, work order lifecycle, failure coding, PM scheduling, backlog management, and reporting.
- Root cause analysis, corrective action, repeat failure elimination, and data-driven problem solving.
- Safety, EHS, cGMP, FDA, Quality, and documentation requirements in a regulated manufacturing environment.
SKILLS/ABILITIES:
- Strong leadership presence with the ability to drive accountability across all shifts.
- Excellent communication skills with the ability to set expectations, provide feedback, and align cross-functional teams.
- Ability to coach supervisors and build leadership capability within the Maintenance organization.
- Ability to balance urgent production needs with long-term reliability discipline.
- Strong analytical skills with the ability to use CMMS, downtime, PM, and work order data to drive action.
WORKING CONDITIONS:
- Manufacturing, packaging, processing, and utility environment.
- Requires regular presence on the manufacturing floor across multiple shifts as needed.
- Requires use of appropriate personal protective equipment in designated areas.
- May require standing, walking, climbing stairs or ladders, bending, kneeling, and inspecting equipment or work areas.
- May be required to respond to urgent operational or maintenance issues outside normal working hours based on business needs.
- Work is performed in a fast-paced, regulated environment requiring adherence to safety, quality, FDA, cGMP, and internal site procedures.
Applicants must be legally authorized to work in the United States without the need for current or future employer-sponsored visa sponsorship.
SALARY RANGE
- $155,000 - $170,000 annually, plus bonus
PDI is pleased to offer a comprehensive and affordable benefits program to our associates, which includes:
- Medical & prescription drug coverage
- Dental / Vision plan
- 401(k) savings plan with company match
- Basic and supplemental life insurance
- Flexible Spending Accounts (FSAs)
- Short- and long-term disability benefits
- Health Advocacy Program / Employee Assistance Program (EAP)
Many other voluntary benefit plans and perks such as: Legal assistance, critical illness, hospital indemnity and accident coverage, discounted home/auto/rental insurance, employee discounts and pet insurance, tuition assistance, referral bonus program, paid parental leave, a health club rebate program and more
At PDI, we are also committed to helping our associates maintain a healthy and sustainable work/life balance and are proud to provide: Sick leave, generous vacation and holiday time, paid parental leave, summer hours, flex place/flex time options
