BFS Maintenance Manager

Nephron Pharmaceuticals Corporation; Columbia (SC); Hybrid; USD 110,000 - 140,000; Full time

Job summary

Nephron Pharmaceuticals Corporation in Columbia, SC seeks a BFS Maintenance Manager to lead state-of-the-art Blow-Fill-Seal maintenance across multiple platforms. You will drive reliability, safety, and regulatory compliance in a sterile manufacturing environment.

Responsibilities include strategic maintenance planning, developing a skilled technician team, overseeing changeovers and validations, and collaborating with Engineering, QA, and Production to reduce downtime and optimize performance

Qualifications

• 7+ years BFS maintenance experience with 3+ years in leadership.
• Associate degree or higher in mechanical/electrical/industrial engineering; tech certs required.
• OEM training in Rommelag, Bosch or similar preferred.

Responsibilities

• Lead and oversee BFS maintenance for multiple platforms to maximize equipment availability.
• Develop long-term overhaul planning and system upgrades.
• Monitor pneumatics, hydraulics, servos, vacuum, and compressors for optimal performance.
• Ensure readiness for changeovers, revalidations, and start-ups.
• Provide hands-on leadership to BFS Technicians and mentor training programs.
• Manage staffing, scheduling, reviews, coaching, and safety culture.
• Ensure FDA, CGMP, and SOP compliance; support deviations and CAPAs.
• Collaborate with Production, QA, and Eng to support installations and validations.

Skills

BFS maintenance leadership

Mechanical and electrical Troubleshoot

BFS equipment knowledge

Preventive & predictive maintenance

Regulatory compliance (FDA CGMP)

Cross-functional collaboration

CMMS usage

Education

Associate degree or higher in Mechanical/Electrical/Industrial Engineering

Technical trade certification in maintenance

OEM training in Rommelag, Bosch etc. preferred

Tools

Rommelag BFS platforms (324/460)

PLCs

Instrumentation & diagnostics tools

Schematic drawing interpretation

Job description

Description

Job Purpose:

The BFS Maintenance Manager leads and directs all aspects of maintenance operations for Blow-Fill-Seal (BFS) equipment, ensuring maximum equipment availability, regulatory compliance, and team development in a sterile pharmaceutical manufacturing environment. This role combines hands‑on technical expertise with strategic planning and personnel management to sustain and improve equipment performance across multiple BFS platforms (e.g., Rommelag 324, 460). The Manager ensures CGMP and safety standards are upheld, oversees long-range maintenance planning, and serves as a critical liaison between Engineering, QA, and Production teams.

Essential Duties and Responsibilities:

Strategic Maintenance Oversight:

• Lead and manage daily, preventive, and predictive maintenance for BFS equipment.
• Develop long-term strategies for overhaul planning, equipment upgrades, and system improvements.
• Monitor and optimize performance of critical systems including pneumatics, hydraulics, servo motors, vacuum, and compressed air systems.
• Ensure readiness and compliance of BFS systems for changeovers, revalidations, and production start-ups.

Team Leadership & Workforce Development:

• Provide hands‑on leadership and technical support to BFS Maintenance Technicians.
• Develop, implement, and maintain a structured technician training program; serve as SME for technical onboarding and continuous development.
• Manage staffing levels, scheduling, performance reviews, coaching, and corrective action when necessary.
• Create a culture of accountability, teamwork, and safety awareness.

Compliance & Quality Systems:

• Ensure all maintenance activities meet FDA, CGMP, and internal SOP requirements.
• Own or support investigations (e.g., deviations, CAPAs, change control) involving equipment and utility systems.
• Approve and maintain SOPs related to BFS maintenance operations.
• Maintain complete and accurate records using CMMS or paper-based documentation.

Cross-Functional Collaboration & Technical Leadership:

• Serve as primary maintenance liaison to Production, QA, and Engineering functions.
• Provide input during equipment installations, validations, and FAT/SAT activities.
• Represent Maintenance during audits, walkthroughs, and cross-department meetings.
• Champion continuous improvement initiatives that increase equipment reliability, reduce downtime, and lower maintenance costs.

Utilities & Support Systems:

• When necessary, oversee maintenance and functionality of supporting systems (e.g., compressed air, vacuum, leak detection, temperature controls, electrical panels).
• Ensure utility integrity during post media maintenance and aseptic area work.

Supplemental Functions:

• Performs all other duties as assigned or apparent.

Job Specifications and Qualifications:

Knowledge:

• Advanced understanding of BFS systems, cleanroom requirements, and aseptic manufacturing practices
• Strong foundation in mechanical and electrical systems, PLCs, power transmission, and instrumentation
• Familiarity with Lean Manufacturing, reliability-centered maintenance, and Six Sigma principles

Technical Competencies and Areas of Expertise:

• Servo Systems, Electrical & Pneumatics Troubleshooting
• BFS Platform Knowledge (Rommelag 324/460 or equivalent)
• Preventive & Predictive Maintenance Strategy
• Packaging Systems (Bosch NTY, Wilco HVLD, Mettler Toledo, etc.)
• Root Cause Analysis / CAPA Implementation
• System Validation Support (I/O, logic verification, requalification)
• Mechanical, Electrical, and Control System Schematics

Education / Experience:

• Associate’s degree or higher in Mechanical, Electrical, or Industrial Engineering preferred
• Technical trade certification in maintenance, pneumatics, or electrical systems required
• OEM training (Rommelag, Bosch, etc.) preferred.
• Minimum 7 years in BFS maintenance, including at least 3 years in a leadership or supervisory capacity
• Demonstrated success managing cross-functional teams and supporting validation/commissioning activities
• Experience with Weiler, Rommelag, or similar shuttle-type BFS systems

Licensing and Certifications:

• OEM certifications in BFS technologies
• Lean Six Sigma, OSHA, or other industry-recognized certifications

Working Conditions / Physical Requirements:

• Ability to lift 50-70 lbs and perform physical tasks (crawling, climbing, bending)
• Exposure to heat, pressurized systems, and mechanical environments
• Standing/walking required for majority of each shift
• Must be able to gown for aseptic cleanroom entry and use PPE
• Required to work rotating 8-hour shifts , must be available for on-call coverage.