Senior Manager, Packaging Maintenance

Job Functional Area
OPS - Maintenance - Eng

Overview

At Technical Operations & Property Services (TOPS) we take care of all IVC assets across the North American region providing enterprise asset management of systems and services encompassing Real Estate and Facilities Management, Reliability & Maintenance, Capital Project & Portfolio Management, Engineering & Technology and Health, Safety & Environmental (HSE). Our goal is to provide innovative services and solutions to the entire IVC network enabling our business to best serve our customers.

 

Reporting to the Reliability & Maintenance pillar lead, the Senior Manager, Packaging Maintenance will build and lead a team of skilled supervisors / leads, technicians, mechanics, specialists, and support staff to troubleshoot effectively and efficiently, repair, maintain and continuously improve and optimize the bottle and blister packaging equipment and lines at our Packaging & Logistics Hub in Anderson, SC.  This position is also responsible for procedures, business practices and tactical execution of work order scheduling/planning, administration and support of the Computerized Maintenance Management System (CMMS) and the MRO (Maintenance, Repair & Operations) Materials Program.

 

In close cooperation with the site Operations Lead, the successful candidate will engage, inspire, empower, and coach their immediate function and all site associates towards operational and execution excellence and timely realization of functional and site targets in safety, quality, productivity, volumes, cost and sustainability. This role will partner with the Senior Director Operations at the Anderson site and Technical Operations peers to shape, continuously refine and deploy operational and asset management strategies to provide a sustained competitive advantage.

 

Partnering with the Operations Excellence team and Technical Improvement Lead, you will create and model a culture of continuous improvement by advocating and applying Maintenance Fundamentals and Lean, Six Sigma, manufacturing asset management and reliability tools and techniques to optimize throughput, cycle-time as well as reliability, availability, longevity, operational safety and overall total cost of ownership for packaging equipment and systems.

Responsibilities

  • Provide technical support and problem solving in the operation, maintenance, and improvement of packaging equipment to mitigate downtime and advance reliability. Resolve escalations in a prompt manner to enable the business to deliver on commitments.
  • Manage performance and development of the Packaging Maintenance team to achieve organizational goals and employee personal and professional growth. Build a strong pipeline of talent and ensure required and appropriate safety and technical training is provided for all team members.
  • Utilize Failure Modes and Effects Analysis (FMEA) and Root Cause Failure Analysis (RCFA) to minimize risk and eliminate failures, perform criticality assessments of equipment, and establish spare part strategy, educate staff on Reliability Centered Maintenance (RCM) and other Operational Excellence efforts centered on reliability.
  • Manages stockroom operation that provides repair parts for critical process equipment, as well as necessary consumables for the plant. Specify and maintain critical spare parts while minimizing on-hand balance of stores items ensuring availability of necessary parts, elimination of obsolete material, adjustment and optimization of stocking levels.
  • Drive a robust program of preventive, predictive and corrective maintenance to maximize personnel safety, machine reliability, overall equipment effectiveness, and product quality. Develop, promote and institutionalize best practices and training.
  • Establishes and manages Key Performance Indicators (KPI’s) to measure functional and / or asset base performance and effectiveness. Continually improves business and operative processes to reduce cost and improve compliance.
  • Determine appropriate allocation of staffing, managing the process for utilization of contracted staff and services where appropriate. Ensure contracts and agreements are in place to provide an adequate labor pool working with vendor leadership to manage performance as needed.
  • Develop department annual budget and monitor/control budget performance against plan. Ensures sound management of resources and expenses to meet and exceed functional and site targets. Optimize the site maintenance budget, long term equipment replacement plans and spare part sourcing strategies.
  • Leads the local Maintenance Agenda and oversees adherence to best practices and processes as adopted across the site and overall region. Collaborate with and contribute to the IVC Maintenance Governance community.
  • Support and maintain compliance with quality systems ensuring properly prepared and accurate maintenance records. Demonstrates commitment to following all company policies and safety requirements from OSHA as well as Federal and State regulations which includes the ability to ensure compliance with safety rules and regulations regarding lockout/tag out, hot work, fall protection etc.
  • Communicate with all site departments to assure cooperation and coordination of services. This would include but is not limited to, operations, planning and accounting departments as well as resources from corporate headquarters.
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Qualifications

Education:

  • Bachelor of Science (BS) degree in Engineering or related technical field and minimum of ten (10) years relevant work experience is required OR Master of Science (MS) in Engineering or related technical field and a minimum of eight (8) years relevant work experience.

Experience:

  • Prior experience serving in maintenance and/or plant reliability roles is required.
  • Prior experience in successfully developing and / or implementing all aspects of an MRO materials management system including utilization of an electronic inventory database system and /or CMMS purchasing/inventory management module is required.
  • Minimum of three (3) years supervision / management experience within a maintenance organization with responsibility for performance management and talent development and professional development for direct reports is
  • Broad-based knowledge of engineering disciplines including Automation & Controls, Mechanical, Electrical, Machine Safety and Reliability is required.
  • Prior experience in a Regulated industry and subject to Government agency and external customer audits and inspections is required. Prior experience working in or for the Consumer Products and / or Life Science Industry is strongly preferred.
  • Experience establishing or managing Preventative Maintenance (PM) program and leading continuous improvement initiatives including development of new PMs and optimizing existing PMs is required.
  • Use of Predictive Maintenance technologies such as mechanical and electrical infrared (thermography), vibration analysis, oil analysis, sonic analysis and a background in reliability-centered maintenance and lean manufacturing. ISO, Lean, Six Sigma, Continuous Improvement strategy and/or Total Productive Maintenance (TPM) Certifications is highly desired
  • Strong knowledge of PLC uploading and downloading of programs with basic modifications of ladder logic, troubleshooting VFDs, ability to read and understand electrical drawing/ hydraulic systems.
  • Organizational skills in planning, goal setting, prioritizing work and coordinating with operations. Strong oral and written communication skills to be able to effectively interface with all levels of personnel, and outside consultants.
  • Knowledge of Maintenance best practices, including but not limited to planning and scheduling, RCM, TPM, and CMMS.
  • Passion for challenging the status quo with ability to drive change, while respecting company values and culture is strongly preferred.
  • Demonstrated track record of establishing strong partnering relationships with key stakeholders driving mutually beneficial collaboration and working effectively across multiple regions and / or functions.
  • Computer proficiency in Microsoft Office and ability to use enterprise software (Maximo or similar CMMS).
  • Ability to read, interpret and apply mechanical drawings, electrical drawings, flowcharts, process and instrumentation diagrams, and/or other technical documentation.
  • Ability to work under pressure and respond with a sense of urgency.
  • Ability and willingness to expand knowledge and scope in maintenance techniques and new equipment technologies.
  • Availability to support equipment maintenance needs for 24/7 operations.
  • This position may require up to 15% domestic travel.

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