Maintenance and Reliability Manager

Job Juncture; Ambler (Montgomery County); On-site; USD 110,000 - 150,000; Full time

Job summary

Job Juncture is seeking an experienced Maintenance Manager/Reliability Leader for a fast-paced chemical manufacturing environment. You will lead asset reliability efforts, spearhead RCFA investigations, and manage mechanical integrity across facilities.

The role requires 10+ years of experience, strong analytical skills, and a track record of reducing downtime, improving OEE, and delivering capital projects on time and budget. Collaboration with Operations, Engineering, and EHS is essential.

Qualifications

• Bachelor's degree in Mechanical Engineering or related field.
• Extensive experience in maintenance leadership and reliability in manufacturing.
• Strong knowledge of regulatory requirements (OSHA, NFPA, EPA, PSM).
• Proven ability to manage budgets, contractors, and capital projects.
• Experience with vibration, thermography, oil analysis and other condition monitoring methods.

Responsibilities

• Develop and implement reliability strategy to improve OEE and reduce downtime.
• Lead RCFA investigations and implement corrective actions.
• Own Mechanical Integrity Program and regulatory compliance.
• Oversee maintenance planning, scheduling, CMMS usage, and work management.
• Lead capital projects from concept through startup and commissioning.
• Manage spare parts, inventory, and vendor relationships.

Skills

Mechanical aptitude

PLC programming

Asset reliability

Root cause analysis

Lean/Six Sigma

TPM/RCM knowledge

Cross-functional leadership

Education

Bachelors in Mechanical Engineering

Electrical or Chemical Engineering acceptable

Tools

CMMS

ERP systems

Power BI / data visualization

Job description

Minimum of 10+ years as a maintenance manager/reliability leader

Working in a fast-paced production environment

Mechanical aptitude a must

PLC programming experience preferred

Chemical Manufacturing maintenance and reliability experience

Excellent understanding and application of regulations and codes ASME, NFPA, OSHA, PSM, API, EPA

Project planning, execution and personnel management required

Demonstrated experience with asset reliability, root cause analysis, preventive and predictive maintenance programs.

Experience managing maintenance budgets, contractors, capital projects, and technical resources.

Strong knowledge of CMMS platforms, ERP systems, maintenance planning systems, and reliability analytics.

Education:

Bachelor’s Degree in Mechanical (preferred), Electrical or Chemical Engineering required

Skills:

Strong mechanical engineering and equipment reliability expertise with demonstrated experience improving asset reliability, reducing downtime, and increasing OEE.

Advanced troubleshooting and root cause analysis skills using structured methodologies such as RCA, 5-Why, Fishbone, FMEA, Fault Tree Analysis, and Reliability Centered Maintenance (RCM).

Proven ability to analyze equipment performance data, failure trends, maintenance costs, and operational metrics to drive data-based decisions and capital recommendations.

Experience developing and optimizing preventive, predictive, and condition-based maintenance programs.

Strong understanding of rotating equipment, pumps, conveyors, filling systems, packaging equipment, pneumatic systems, hydraulic systems, compressors, and utility systems.

Experience utilizing reliability tools and technologies including vibration analysis, thermography, oil analysis, ultrasonic inspection, and condition monitoring systems.

Ability to identify chronic equipment losses and develop sustainable solutions that improve reliability, throughput, quality, and safety.

Demonstrated project management skills, including capital project justification, budgeting, equipment installation, commissioning, FAT/SAT participation, and startup support.

Strong understanding of maintenance planning, scheduling, spare parts optimization, CMMS systems, and work order management.

Experience applying Lean Manufacturing, Six Sigma, TPM, and Continuous Improvement methodologies to improve operational performance.

Knowledge of OSHA regulations, PSM requirements, NFPA standards, machine safety, LOTO, and engineering standards applicable to manufacturing operations.

Strong analytical skills with proficiency in Excel, ERP systems, CMMS platforms, Power BI, and data visualization tools.

Ability to collaborate effectively with Operations, Maintenance, Engineering, EHS, Quality, Procurement, and external contractors.

Excellent communication and influencing skills with the ability to lead cross-functional teams without direct authority.

Ability to operate effectively in a fast-paced manufacturing environment while managing multiple projects and competing priorities.

Demonstrated ownership mindset with a passion for driving reliability, eliminating losses, and improving overall equipment performance.

DUTIES & RESPONSIBILITIES:

1. Asset Reliability & Equipment Performance

• Develop and implement the site's reliability strategy to improve OEE, reduce unplanned downtime, and increase asset availability.
• Establish, manage, and continuously improve preventive, predictive, and condition-based maintenance programs.
• Lead Root Cause Failure Analysis (RCFA) investigations and implement sustainable corrective actions.
• Analyze equipment performance, downtime trends, maintenance costs, and operational data to identify improvement opportunities.
• Develop long-term asset management, lifecycle cost, refurbishment, and replacement strategies.
• Drive data-based decision making for equipment upgrades, modernization initiatives, and capital investments.
• Establish asset criticality rankings and reliability improvement roadmaps.
• Continuously improve MTBF, MTTR, maintenance schedule compliance, and asset utilization.
• Ensure reliability and performance of mechanical, electrical, pneumatic, hydraulic, and utility systems.
• Provide oversight of electrical distribution systems, motor control centers (MCCs), VFDs, power systems, and facility electrical infrastructure.
• Maintain reliability of instrumentation, sensors, transmitters, control valves, safety systems, and process monitoring equipment.
• Support the maintenance and lifecycle management of PLCs, HMIs, SCADA systems, industrial networks, and automation platforms.
• Lead troubleshooting of complex mechanical, electrical, controls, and automation failures.
• Develop equipment standards and maintenance strategies for critical electrical and control assets.
• Identify automation opportunities that improve safety, reliability, efficiency, and operational performance.

3. Mechanical Integrity & Regulatory Compliance

• Own the site's Mechanical Integrity Program and ensure compliance with applicable company standards and regulatory requirements.
• Ensure inspection, testing, maintenance, and certification of critical equipment, pressure systems, piping, utilities, process equipment, and fire protection systems.
• Support Process Safety Management (PSM), environmental compliance, and risk reduction initiatives.
• Ensure adherence to OSHA, EPA, NFPA, local codes, insurance requirements, and recognized engineering standards.
• Manage statutory inspections, audits, permits, corrective actions, and compliance documentation.
• Ensure process safety critical equipment maintains required levels of integrity and reliability.

4. Maintenance Planning, Scheduling & Execution

• Own and continuously improve maintenance planning, scheduling, and work management processes.
• Ensure effective use of CMMS, work order systems, preventive maintenance schedules, and maintenance reporting tools.
• Develop and maintain maintenance procedures, SOPs, job plans, and equipment care standards.
• Drive planning and execution excellence to maximize wrench time and maintenance productivity.
• Establish shutdown, outage, and turnaround maintenance strategies.
• Provide technical leadership during significant equipment failures and emergency maintenance situations.
• Ensure maintenance activities are completed safely, efficiently, and with minimal operational disruption.

5. Critical Spare Parts & Inventory Management

• Develop and manage critical spare parts strategies based on equipment criticality, business risk, and lead times.
• Ensure appropriate inventory levels are maintained for critical production, utility, safety, and process safety equipment.
• Partner with Supply Chain and Procurement to optimize inventory investment while minimizing operational risk.
• Monitor equipment obsolescence and develop mitigation strategies.
• Implement spare parts standardization and lifecycle management programs.

6. Maintenance Leadership & Talent Development

• Provide direct leadership for maintenance personnel, supervisors, reliability resources, and support staff.
• Establish clear performance expectations, goals, accountability measures, and development plans.
• Lead hiring, onboarding, coaching, succession planning, performance management, and employee development activities.
• Build a high-performance culture focused on safety, reliability, technical excellence, accountability, and continuous improvement.
• Develop technical competency programs, certification pathways, and structured training plans.
• Support Maintenance Supervisors in managing frontline maintenance technicians and mechanics.
• Develop future technical and leadership talent within the maintenance organization.
• Establish contractor safety, qualification, onboarding, and performance management processes.
• Manage relationships with OEMs, equipment suppliers, engineering firms, contractors, and service providers.
• Review and approve contractor scopes of work, technical specifications, bid packages, quotations, and service agreements.
• Monitor contractor performance through KPIs, SLAs, quality metrics, safety performance, and project deliverables.
• Ensure all contractors comply with site safety, environmental, quality, and operational requirements.
• Drive cost savings and performance improvements through strategic vendor partnerships.
• Lead maintenance and reliability aspects of capital projects from concept through startup and commissioning.
• Provide technical input for equipment selection, FAT/SAT reviews, installation, commissioning, and operational handover.
• Develop equipment standards, technical specifications, and engineering requirements for new projects.
• Partner with Engineering and Operations to implement equipment upgrades and capacity improvement projects.
• Prepare business cases, ROI analyses, and financial justifications for capital expenditures.
• Support equipment modernization and technology advancement initiatives.

9. Cross-Functional Leadership & Business Partnership

• Partner closely with Operations, Engineering, Quality, EHS, Finance, Procurement, and Supply Chain functions.
• Lead cross-functional teams focused on reliability improvements, loss elimination, process optimization, and operational excellence.
• Align maintenance priorities with production, quality, safety, service, and financial objectives.
• Act as the site's technical authority for reliability, maintenance, and asset management decisions.
• Effectively communicate risks, priorities, and recommendations to site leadership and executive management.

10. Continuous Improvement & Operational Excellence

• Lead TPM, Lean Manufacturing, Reliability-Centered Maintenance (RCM), Six Sigma, and continuous improvement initiatives.
• Establish maintenance excellence standards and asset care programs.
• Drive 5S implementation within maintenance and technical areas.
• Eliminate chronic equipment losses through structured problem-solving methodologies.
• Implement predictive maintenance technologies including vibration analysis, thermography, oil analysis, ultrasonics, and condition monitoring.
• Develop and maintain maintenance and reliability KPI dashboards.

11. Facilities & Utilities Management

• Ensure reliability and maintenance of facility infrastructure and utility systems.
• Manage maintenance strategies for electrical distribution, compressed air, HVAC, chillers, boilers, process cooling, wastewater, and fire protection systems.
• Support facility improvement projects and infrastructure reliability initiatives.
• Ensure utility systems can support current and future manufacturing requirements.
• Develop and manage annual maintenance operating and capital budgets.
• Monitor maintenance spending, contractor costs, inventory investment, and project expenditures.
• Identify opportunities to reduce Total Cost of Ownership (TCO) while improving reliability and operational performance.
• Develop long-range asset replacement and capital investment plans.
• Ensure responsible stewardship of company assets and resources.

Responsibilites can be added based on Operations and Capital project needs.