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 supports safety, quality, a positive work environment, customer requirements, and manufacturing needs through the Toyota Production System (TPS), while coordinating maintenance activities to improve productivity and reduce costs. The position oversees maintenance of production equipment, facilities, and utility systems; equipment commissioning; preventative and predictive maintenance; spare-parts control; maintenance budgets, capital planning, headcount, and performance indicators. It leads maintenance supervisors and team members, applies and teaches TPS techniques, and develops continuous improvement, standardization, safety, quality, and 5S practices. The manager also supports team-member development through evaluation, training plans, coaching, feedback, and corrective action. The work takes place in an open-office environment and various manufacturing settings, including a standard automotive plant with moderate noise. PPE may be required in designated areas, and conditions may occasionally include cold, dust, heat, or odors. Travel of up to 10% is required. Physical demands include walking, sitting, and standing for extended periods; inspecting, adjusting, and operating equipment; occasional climbing, bending, reaching, grasping, and manipulating items; and occasionally lifting up to 30 pounds.

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.
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 techniques, and equipment and machine operation.
General understanding and working knowledge of basic engineering principles.
Working knowledge of automotive industry equipment and production systems.
General understanding and practical work experience with maintenance systems and processes.
Practical experience applying TPS 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 to prepare reports, manuals, and proposals.
Knowledge of budgets, costing, scheduling, customer requirements, and preventative maintenance programs.
Knowledge of safety and environmental regulations.
Negotiation skills with external vendors, suppliers, and customers.
Advanced math skills.
Strong leadership, problem-solving, people, organization, and planning skills.
Ability to work in a fast-paced, multicultural environment.
Excellent written, verbal, and interpersonal communication skills; strong verbal and written English skills.
Ability to plan, supervise, and perform functions of assigned areas.
Ability to communicate and work well with others in a team environment, and to work independently with good judgment.
Ability to multitask, handle diversity, lead problem resolution, prioritize tasks, work efficiently within time constraints and deadlines, and handle stressful situations calmly.
Solid working knowledge and experience with Microsoft Office and other computer-based applications, such as Word, Excel, PowerPoint, Lotus Notes/Outlook, and the Internet.
Ability to meet the role’s physical demands, including inspecting, adjusting, and operating equipment and occasionally lifting up to 30 pounds.
Must be willing to travel up to 10% of the time.

Nice To Haves

Manufacturing experience, preferably in the automotive industry.

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 preventative 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, productivity, cost, health, and morale.
Direct and coordinate maintenance, repair, and installation work to support continuous production.
Direct and control maintenance of plant grounds and utility systems.
Lead maintenance supervision and team members in using and learning TPS techniques.
Coordinate standardization of processes and methods.
Identify maintenance problems and eliminate waste.
Develop and monitor a Maintenance continuous-improvement system.
Develop maintenance cost reductions and manage the annual plan, budget, KPIs, operating efficiency, and cost control.
Ensure maintenance hoshin goals are met and on track.
Plan, review, and approve maintenance budget items and short- and long-term capital planning.
Approve requisitions for new and replacement parts, supplies, machinery, and equipment for maintenance areas.
Review and plan monthly headcount for labor-cost control.
Track maintenance KPIs, including machine uptime and downtime, and lead problem solving for negative trends or unmet goals.
Prepare and report monthly performance reports with targets and present operational performance weekly.
Participate in management discussions and planning for cost reduction, product improvement, and problem solving.
Monitor maintenance operations to ensure scheduled work, material needs, manpower, skills, equipment, facilities, methods, and related requirements are appropriately managed.
Monitor projects to ensure safety and quality standards are met.
Plan and implement maintenance procedures and policies to keep equipment, tools, facilities, and utilities in acceptable repair.
Implement and maintain a clean, organized department through 5S activity.
Develop and maintain positive team-member relations based on trust, respect, fairness, communication, teamwork, and harmony.
Develop team members through performance evaluations, training plans, feedback, coaching, corrective action, and cascade training; update training matrices and schedule needed training.