Maintenance & Reliability Manager

Westrock Coffee Company; Concord, Northern (NC, KY); Hybrid; USD 110,000 - 150,000; Full time

Job summary

Westrock Coffee Company seeks a Maintenance and Reliability Manager to lead the production maintenance program, develop preventative and predictive maintenance plans, and maximize yield, uptime, and throughput in a large-scale beverage manufacturing operation.

You will plan, coordinate, and execute work to ensure safety, quality, and regulatory compliance while directing technicians and engineers to install, repair, and maintain all equipment across the plant.

Qualifications

• Bachelor's degree in a technical field with 7–10 years of maintenance management experience or equivalent
• Experience using and optimizing CMMS to improve maintenance operations
• Knowledge of maintenance inventory systems and accounting practices
• Ability to conduct root cause analysis and identify sustainable corrective actions
• Proven track record developing and managing preventive maintenance programs
• Budget development and management experience
• Commitment to a safe work environment and safety culture
• Ability to develop employees and foster a culture of excellence and "First Time Right" execution
• Strong written and verbal communication skills
• Proficiency with Microsoft Office and ability to multi-task across priorities
• Experience with Lean manufacturing tools (5S, VSM, OEE, Kaizen) preferred

Responsibilities

• Directs and enforces the maintenance safety program and reviews safety records
• Coordinates major maintenance and repair work to minimize production impact
• Ensures compliance with environmental, food safety and occupational safety regulations
• Leads CMMS optimization to track work orders, parts, and maintenance history
• Plans and implements plant improvements and capital projects
• Develops and maintains documentation and up-to-date procedures for maintenance staff
• Provides technical guidance and training to maintenance workforce
• Analyzes KPIs like asset utilization, maintenance cost, PM compliance, uptime and schedule adherence
• Leads root cause analysis and corrective/preventive actions as needed
• Manages Maintenance budget and cross-functional collaboration for reliability improvements
• Recruits and develops maintenance personnel and supervises supervisors
• Collaborates on safety, quality, and regulatory programs across departments

Skills

Root cause analysis

Leadership

Maintenance planning

Budget management

Cross-functional collaboration

Safety culture

Analytical thinking

Communication skills

Education

Bachelor's degree in a technical field

Tools

CMMS (Maintenance Management System)

Microsoft Office Suite

Inventory management systems

Job description

The Maintenance and Reliability Manager will be responsible for directing production maintenance and developing maintenance plans with a strong focus on preventative and predictive measures to maximize yield, uptime, and process throughputs in a large-scale Coffee, Tea, and Liquid Extracts manufacturing operation. This role will encompass planning, coordination and executing work activities to ensure compliance with Food Safety, Quality, and Regulatory requirements as well as the leadership of individuals who install, repair, and maintain all manufacturing equipment.

Key Responsibilities:

• Ensures compliance with safety, health, and environmental policies and procedures to ensure a safe and healthy work environment
• Directs, maintains, and enforces the maintenance safety program, and reviews safety records to uphold and reinforce a safety culture for all maintenance and plant employees
• Ensures compliance with city, county, state, and federal regulations related to the maintenance department activities at all times (Environmental, Food and Occupational Safety)
• Communicates directly with the operations department to coordinate major maintenance and repair work in all process areas that could impact manufacturing operations
• Communicates directly with the quality department to ensure all maintenance work is performed in accordance with all plant food safety and quality policies
• Implements programs and procedures (Master Sanitation, 5S, GMPs,etc.) to ensure plant and work area cleanliness
• Assists with the planning and implementation of all plant improvements and Capital projects as required
• Communicates on technical issues with the maintenance workforce and engineers to both understand problems and collaborate on solutions.
• Ensures that all operating and training manuals, technical prints, and other technical documentation used by the maintenance department are current and up to date
• Ensures that all maintenance technicians are trained on the most updated versions of operating procedures and ensures the continual technical training and education of the all maintenance department employees
• Monitors and directs the predictive and preventive maintenance programs of plant equipment and systems to minimize unplanned downtime, anticipate and solve technical problems in a timely manner, and to identify opportunities for continuous improvement
• Ensures the inspection and repair of all maintenance shop equipment and tools
• Ensures that the computerized maintenance management system (CMMS) is optimized to accurately track work requests, work orders, spare parts, and equipment maintenance history. Prepares reports, analyzes data, and generates recommendations for improving plant operations and solving maintenance related problems
• Develops plans to improve the long-term equipment reliability by increasing appropriate PM/PdM practices to provide early detection of anomalies and reduce equipment downtime due to unforeseen failures
• Lead or participate in Root Cause Analysis and Corrective/Preventive Action Requests as needed
• Ensures that Management of Change protocols (MOC) are implemented and followed by craftsmen to improve documentation, procedures, equipment reliability, and regulatory compliance
• Ensures that maintenance technicians are adequately trained, equipped, and motivated so that the maintenance program can be accomplished in a safe, timely, and cost-effective manner
• Develops maintenance supervisors in the area of technical knowledge, teamwork, leadership, and continuous improvement
• Communicates regularly with all maintenance technicians both individually and as a group to ensure good two-way communication concerning maintenance issues
• Assists with the hiring of maintenance personnel
• Initiates and supports projects that improve efficiency and/or reduce operating costs
• Tracks, analyzes, and improves key maintenance performance indicators (KPIs) such as asset utilization, maintenance costs, PM compliance, uptime, and schedule compliance
• Participates in the development of KPIs, objectives, and plans to improve overall plant efficiency as a member of the manufacturing leadership
• Initiates, implements, and manages the plant maintenance program based on best practices and Lean Manufacturing techniques with an emphasis on planning/scheduling and preventive/predictive maintenance
• Monitors the use, and inventory levels of spare parts, maintenance supplies, and other equipment to balance availability and cost
• Development and manage the maintenance department's budget and operations' departments required inputs
• Ensure employee performance reviews are completed based on job descriptions, competency, knowledge, and contributions of maintenance employees

Requisition Number

6549

Shift

First

Qualification

• Bachelor's Degree in a technical field plus 7-10 years previous maintenance management experience ; or equivalent combination of education and experience
• Experience utilizing and optimizing CMMS systems to improve maintenance operations and manufacturing performance
• Knowledge of Maintenance inventory systems and accounting practices and procedures
• Ability to conduct Root Cause Analysis and identify sustainable long-term corrective actions
• Demonstrated experience in developing and/or managing an effective preventive maintenance program
• Budget development and management experience
• Ability to ensure a safe work environment and develop a culture of safety within the maintenance department
• Ability to develop employees and set high standards for execution to establish a culture of excellence and "First Time Right" mentality within the maintenance department
• Excellent written and verbal communication skill
• Working Knowledge of Microsoft Office Suite
• Ability to multi-task and handle competing priorities
• Ability to work cross-functionally and develop the technical knowledge and abilities of all plant employees to ensure sustainable reliability
• Strong ability to time manage
• Individual and team development capabilities
• Previous use or working knowledge of the Lean manufacturing tools, e.g. 5S, VSM, OEE, Kaizen, SICs, and Visual Factory strongly preferred

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