Senior Maintenance Manager

DSJ Global; Rockford (IL); On-site; USD 169,000 - 210,000; Full time

Job summary

DSJ Global is seeking a Senior Maintenance & Facilities Manager to lead maintenance, reliability, utilities, and facilities for a manufacturing operation. The role aims to maximize uptime, improve asset reliability, reduce risk, and ensure safe, cost-efficient plant operations.

Collaboration with Operations, Engineering, Quality, and EHS is essential to support production goals and long-term asset performance.

Qualifications

• 10+ years of maintenance leadership experience within a manufacturing environment.
• Bachelor's degree in Engineering or a related technical discipline preferred.
• Strong knowledge of preventive, predictive, and reliability-centered maintenance practices.
• Expertise managing production equipment, utilities, and facility infrastructure, including HVAC, electrical distribution, compressed air, water systems, fire protection, and other building systems.
• Experience implementing maintenance excellence initiatives, continuous improvement programs, and equipment reliability strategies.
• Proficiency with CMMS/EAM systems, maintenance planning, scheduling, and asset management.
• Strong understanding of root cause analysis methodologies (5 Whys, Fishbone, FMEA, RCA, etc.).
• Knowledge of OSHA regulations, environmental requirements, GMPs, and other applicable compliance standards.
• Experience leading capital projects, shutdowns, facility upgrades, and asset replacement programs.
• Demonstrated ability to develop and lead high-performing maintenance teams.
• Strong analytical, problem-solving, communication, and project management skills.

Responsibilities

• Safety, Compliance & Quality: Ensure all maintenance and facilities activities comply with applicable safety, environmental, and regulatory requirements.
• Lead programs related to lockout/tagout, confined space entry, hot work, contractor safety, and risk reduction.
• Partner with Quality and EHS teams to maintain compliance with food safety, GMP, and other industry-specific standards.
• Conduct audits, investigations, and corrective action initiatives to drive continuous improvement in safety performance.
• Promotion of a culture focused on safety, compliance, and operational excellence.
• Maintenance & Reliability Leadership: Lead daily maintenance operations across production assets to ensure safe and reliable equipment performance.
• Drive execution of preventive, predictive, and condition-based maintenance programs.
• Prioritize maintenance activities based on asset criticality and production requirements.
• Lead troubleshooting efforts and implement long-term solutions to recurring equipment issues.
• Monitor maintenance KPIs and reliability metrics to improve asset performance.
• Facilities & Utilities Management: Oversee maintenance and reliability of facility infrastructure and utility systems.
• Ensure building systems operate efficiently and in compliance with applicable regulations.
• Manage external service providers and contractors supporting facility operations.
• Develop and execute long-term plans for infrastructure improvements and capacity expansion.
• Lead site-wide initiatives focused on equipment reliability, loss elimination, and maintenance best practices.
• Partner with operations teams to strengthen operator engagement in equipment care and basic maintenance activities.
• Establish and maintain maintenance standards, procedures, and reliability strategies.
• Drive continuous improvement through data analysis, audits, and performance reviews.
• Planning & Asset Management: Ensure effective maintenance planning and scheduling processes.
• Manage spare parts inventories and critical spare strategies.
• Maintain accurate asset records, preventive maintenance procedures, and system documentation within the CMMS.
• Review backlog, PM compliance, and work execution performance to identify improvement opportunities.
• Lead, coach, and develop maintenance supervisors, planners, and technicians.
• Build a culture of accountability, ownership, and continuous improvement.
• Support workforce development through training, succession planning, and technical skill enhancement.
• Foster collaboration between Maintenance, Operations, Engineering, Quality, and EHS teams.
• Budgeting & Capital Projects: Develop and manage maintenance operating and capital budgets.
• Lead asset lifecycle planning and capital investment strategies.
• Oversee maintenance-related capital projects from justification through execution.
• Utilize reliability and performance data to support investment decisions and improve operational efficiency.

Skills

Maintenance leadership

Asset reliability

Safety & compliance

Project management

Data analysis

Education

Bachelor's degree in Engineering or related technical discipline

Tools

CMMS/EAM systems

Job description

Salary: GBP125000 - GBP155000 per annum

Position Summary

The Senior Maintenance & Facilities Manager provides strategic leadership for all maintenance, reliability, utilities, and facilities functions within a manufacturing operation. This role is responsible for maximizing equipment uptime, improving asset reliability, reducing operational risk, and ensuring safe, efficient, and cost-effective plant operations. The position partners closely with Operations, Engineering, Quality, and EHS teams to support production goals, regulatory compliance, and long-term asset performance.

Key Qualifications

• 10+ years of maintenance leadership experience within a manufacturing environment.
• Bachelor's degree in Engineering or a related technical discipline preferred.
• Strong knowledge of preventive, predictive, and reliability-centered maintenance practices.
• Expertise managing production equipment, utilities, and facility infrastructure, including HVAC, electrical distribution, compressed air, water systems, fire protection, and other building systems.
• Experience implementing maintenance excellence initiatives, continuous improvement programs, and equipment reliability strategies.
• Proficiency with CMMS/EAM systems, maintenance planning, scheduling, and asset management.
• Strong understanding of root cause analysis methodologies (5 Whys, Fishbone, FMEA, RCA, etc.).
• Knowledge of OSHA regulations, environmental requirements, GMPs, and other applicable compliance standards.
• Experience leading capital projects, shutdowns, facility upgrades, and asset replacement programs.
• Demonstrated ability to develop and lead high-performing maintenance teams.
• Strong analytical, problem-solving, communication, and project management skills.

Primary Responsibilities

Safety, Compliance & Quality

• Ensure all maintenance and facilities activities comply with applicable safety, environmental, and regulatory requirements.
• Lead programs related to lockout/tagout, confined space entry, hot work, contractor safety, and risk reduction.
• Partner with Quality and EHS teams to maintain compliance with food safety, GMP, and other industry-specific standards.
• Conduct audits, investigations, and corrective action initiatives to drive continuous improvement in safety performance.
• Promote a culture focused on safety, compliance, and operational excellence.

Maintenance & Reliability Leadership

• Lead daily maintenance operations across production assets to ensure safe and reliable equipment performance.
• Drive execution of preventive, predictive, and condition-based maintenance programs.
• Prioritize maintenance activities based on asset criticality and production requirements.
• Lead troubleshooting efforts and implement long-term solutions to recurring equipment issues.
• Monitor maintenance KPIs and reliability metrics to improve asset performance.

Facilities & Utilities Management

• Oversee maintenance and reliability of facility infrastructure and utility systems.
• Ensure building systems operate efficiently and in compliance with applicable regulations.
• Manage external service providers and contractors supporting facility operations.
• Develop and execute long-term plans for infrastructure improvements and capacity expansion.
• Lead site-wide initiatives focused on equipment reliability, loss elimination, and maintenance best practices.
• Partner with operations teams to strengthen operator engagement in equipment care and basic maintenance activities.
• Establish and maintain maintenance standards, procedures, and reliability strategies.
• Drive continuous improvement through data analysis, audits, and performance reviews.

Planning & Asset Management

• Ensure effective maintenance planning and scheduling processes.
• Manage spare parts inventories and critical spare strategies.
• Maintain accurate asset records, preventive maintenance procedures, and system documentation within the CMMS.
• Review backlog, PM compliance, and work execution performance to identify improvement opportunities.
• Lead, coach, and develop maintenance supervisors, planners, and technicians.
• Build a culture of accountability, ownership, and continuous improvement.
• Support workforce development through training, succession planning, and technical skill enhancement.
• Foster collaboration between Maintenance, Operations, Engineering, Quality, and EHS teams.

Budgeting & Capital Projects

• Develop and manage maintenance operating and capital budgets.
• Lead asset lifecycle planning and capital investment strategies.
• Oversee maintenance-related capital projects from justification through execution.
• Utilize reliability and performance data to support investment decisions and improve operational efficiency.

Why Consider This Opportunity?

• Senior leadership role with significant impact on plant performance and reliability.
• Opportunity to lead maintenance, facilities, utilities, and reliability functions across a complex manufacturing operation.
• High visibility position with cross-functional interaction and influence.
• Ability to drive long-term reliability improvements, capital investments, and operational excellence initiatives.