Maintenance Manager

Toyota Boshoku America•Lawrenceville, IL

About The Position

The Maintenance Manager leads the Maintenance department in accordance with company policies, manufacturing standards and methods, product requirements, quality standards, and production schedules. The role ensures safety, quality, a positive work environment, customer requirements, and manufacturing needs are met through the Toyota Production System (TPS) philosophy. It coordinates maintenance activities to improve productivity and reduce costs. The manager oversees maintenance of production equipment, facilities, and utility systems; equipment specification, installation, and commissioning; predictive and preventive maintenance; and spare parts control. The role leads maintenance supervisors and team members, applies and teaches TPS techniques, standardizes processes, identifies and eliminates waste, and develops continuous improvement and cost-reduction activities. The position manages annual plans, budgets, KPIs, capital planning, headcount reviews, machine uptime and downtime, and monthly performance reporting. It also ensures maintenance work, projects, equipment, facilities, and utilities meet safety and quality standards; maintains an organized department through 5S; and supports team-member development through evaluations, training plans, coaching, feedback, corrective action, and training coordination. Work takes place in an open office and various manufacturing environments, including a standard automotive plant with moderate noise. Required PPE may include safety glasses, steel-toe shoes, Kevlar sleeves, and hearing protection. The role may involve occasional exposure to cold, dust, heat, or odors and requires willingness to travel up to 10% of the time.

Requirements

Bachelor’s degree in Engineering, Industrial Maintenance, or a related field, or an equivalent combination of education and relevant experience.
More than 8 years of relevant work experience in a manufacturing environment; automotive experience preferred.
More than 4 years of functional leadership experience as a supervisor in a manufacturing or maintenance environment.
Thorough understanding of company products, trade terminology, maintenance and repair operations, manufacturing processes, quality management and control systems, and equipment and machine operation.
General understanding of basic engineering principles.
Working knowledge of automotive industry equipment and production systems.
Understanding and practical work experience with maintenance systems and processes.
Practical experience applying Toyota Production System principles in an automotive environment.
Strong knowledge of welding, hydraulics, pneumatics, PLC programming, injection, electrical, and mechanical environments.
Ability to maintain records and compile data for reports, manuals, and proposals.
Knowledge of budgets, costing, scheduling, customer requirements, and preventive maintenance programs.
Knowledge of safety and environmental regulations.
Negotiation skills for working with external vendors, suppliers, and customers.
Advanced math skills.
Strong leadership, problem-solving, organization, planning, and people skills.
Ability to work in a fast-paced, multicultural environment.
Excellent written, verbal, and interpersonal communication skills, including strong verbal and written English.
Ability to plan, supervise, and perform functions of assigned areas.
Ability to work well with others and function independently with good judgment in a team environment.
Ability to multitask, handle diversity, and provide leadership through problem resolution.
Ability to prioritize multiple tasks, meet time constraints and deadlines, and handle stressful situations calmly.
Solid working knowledge and experience with Microsoft Office and other computer-based applications.
Willingness to travel up to 10% of the time.
Ability to perform the essential functions with or without reasonable accommodation.

Nice To Haves

Automotive manufacturing experience.

Responsibilities

Direct maintenance activities on production equipment, facilities, and utility systems to provide a reliable production platform.
Specify, install, and commission new equipment.
Develop and implement predictive and preventive maintenance programs with production management.
Oversee the spare parts control program.
Provide direction and motivation to group leaders, supervisors, and team members, emphasizing safety, quality, efficiency, cost, productivity, and morale.
Direct and coordinate repair, maintenance, and installation of machines, tools, and equipment to support continuous production.
Direct and control maintenance of plant grounds, buildings, and utility systems.
Lead maintenance supervision and team members in learning, applying, and teaching Toyota Production System techniques.
Coordinate standardization of processes and methods, identify maintenance problems, and eliminate waste.
Develop and monitor a Maintenance continuous improvement system and develop cost reductions.
Develop and manage the annual plan, budget, KPIs, operating efficiency, and cost control.
Ensure Maintenance hoshin goals are met and remain on track.
Plan, review, and approve maintenance budget items and long- and short-term capital planning.
Approve requisitions for new and replacement parts, supplies, machinery, and equipment.
Review and plan monthly headcount for labor cost control.
Review and track Maintenance KPIs, manage machine uptime and downtime, and lead problem solving for negative trends or unmet goals.
Generate monthly reports and report performance against targets.
Participate in management discussions and planning for cost reduction, product improvement, and problem solving; present operational performance weekly.
Monitor maintenance operations to ensure scheduled work and material needs are met and manpower, skills, equipment, facilities, and methods are used appropriately.
Monitor projects to ensure safety and quality standards are met.
Plan and implement procedures and policies to keep equipment, tools, facilities, and utilities in acceptable repair.
Implement, monitor, and maintain a clean and organized department through 5S activity.
Develop and maintain positive team-member relations based on mutual trust, dignity, respect, fairness, consistency, communication, teamwork, and harmony.
Support team-member development through performance evaluations, training plans, feedback, coaching, corrective action, and cascade training.
Update the team-member training matrix and schedule needed training.