Plant Maintenance & Reliability Lead

FPC Franchise; Madison (WI); On-site; USD 95,000 - 150,000; Full time

Job summary

The Maintenance Manager at FPC Franchise will lead the plant maintenance department to ensure production equipment operates as designed and products are delivered on time for customers. This role owns the scope of work, schedule, budget, and resources required to execute daily maintenance activities and support overall plant success.

This position advances preventive and predictive programs, strengthens equipment reliability, and drives a culture of continuous improvement to support reliable

Qualifications

• Four-year engineering degree in mechanical, electrical, or chemical.
• At least 5 years of maintenance experience in a chemical or pharmaceutical manufacturing environment.
• At least 5 years of previous supervisory experience.
• Proven ability to maintain high standards aligned with corporate values, hold people accountable, and have crucial conversations.
• Demonstrated experience effectively managing maintenance strategies.
• Excellent prioritization, resource allocation, and business analytics skills.
• Superior interpersonal, oral, and written communication skills with strong team orientation.
• Ability to develop, energize, and empower others.
• Desire to walk the floor and work closely with plant personnel to solve problems and implement improvements.
• Sense of urgency and ability to engage people positively to move projects forward on an expedited timeframe.
• In-depth knowledge of process technologies, such as chemical processing and environmental compliance equipment.
• Previous experience performing equipment reliability studies, developing preventive maintenance programs, and making recommendations for long-term improvements.

Responsibilities

• Minimize plant equipment downtime to ensure production demands are met.
• Utilize the CMMS system to effectively plan preventive maintenance needs within the plant.
• Address and eliminate identified safety issues requiring engineering controls at the plant.
• Lead plant maintenance teams to continually drive performance improvements of capital assets.
• Manage the performance and development of the plant maintenance team.
• Lead Kaizen activities and model a continuous improvement mindset.
• Provide opportunities for team members to learn new skillsets and grow professionally when possible.
• Hire, mentor, and train new engineers and support staff at the Portage plant.
• Partner with business development and process design teams to develop effective engineering solutions for new, high-quality products.
• Create cost-effective designs that meet project goals and follow EHS principles.
• Ensure the maintenance team follows SOPs and safety protocols to effectively execute daily maintenance.
• Conduct daily pre-work safety tailgate meetings to keep safety top of mind at the start of each day or shift.
• Develop and improve maintenance strategies for the site, including strategies for new equipment coming to the site.
• Coordinate closely with contractors to prioritize work and ensure activities are completed on time and within budget.
• Ensure plant drawings, including layouts and P&IDs, are created and kept current as changes occur.
• Communicate project status, timelines, and spending profiles to internal customers.
• Help develop and improve Encapsys maintenance policies and procedures.
• Ensure maintenance teams complete all assigned training.
• Optimize spare parts management, review asset classification and strategy, and align maintenance strategy accordingly.
• Maintain Portage equipment maintenance records and Engineering and Maintenance files to ensure drawing and information accuracy.
• Provide repair cost estimates and timelines.
• Identify risks and opportunities and create countermeasures.
• Wear a respirator as required by the task being performed or chemical safety data sheets.
• Maintain daily visibility on the production floor by walking areas of responsibility, engaging associates, verifying adherence to rules and procedures, identifying at-risk behaviors or hazardous conditions, and taking immediate action to address concerns.

Skills

Leadership

Prioritization

Communication

Walk the floor

Problem solving

Team leadership

Analytical thinking

Education

Four-year engineering degree (mechanical, electrical or chemical)

Tools

PLC ladder logic

CAD

Data historian

Ultrasound

Vibration monitoring

Thermal imaging

Predictive maintenance technologies

Job description

The Maintenance Manager at FPC Franchise will lead the plant maintenance department to ensure production equipment operates as designed and products are delivered on time for customers. This role owns the scope of work, schedule, budget, and resources required to execute daily maintenance activities and support overall plant success.

This position advances preventive and predictive programs, strengthens equipment reliability, and drives a culture of continuous improvement to support reliable