Position: Maintenance Director
Reports to: Plant Manager
Position location: 602 E. Walnut Street, Watseka, IL 60970
Position Mission:
The Maintenance Director is responsible for leading and managing all maintenance operations within a metal fabrication facility. This includes maintaining legacy equipment, overseeing facility infrastructure, and directing tool room functions. The role focuses on maximizing equipment uptime, promoting operational efficiency, and ensuring workplace safety. Key duties include developing and executing preventive and predictive maintenance strategies, coordinating with external vendors for service and repair needs, and managing a team of technicians, toolmakers, and facilities personnel.
Compensation: $100,000 – $150,000.
Salaried, Exempt
Essential Roles and Responsibilities Overview:
Maintenance Leadership
- Design and execute a strategic maintenance plan that minimizes equipment downtime and optimizes performance, with a focus on aging fabrication machinery.
- Lead troubleshooting efforts, identify root causes, and implement corrective actions to resolve equipment issues.
- Manage and monitor preventive and predictive maintenance using a Computerized Maintenance Management System (CMMS).
- Align maintenance schedules with production priorities to minimize disruption.
- Employ predictive maintenance tools such as vibration analysis and thermography.
- Coordinate service, inspections, retrofits, and warranty work with OEMs and third-party providers.
- Oversee vendor performance and manage maintenance service contracts.
Tool Room Management
- Supervise the tool room team in the design, fabrication, maintenance, and storage of dies, jigs, fixtures, and specialized tooling.
- Ensure tools are properly maintained, calibrated, and available to support production needs.
- Assess tool performance and lead improvements or redesigns as needed.
- Manage the tool inventory lifecycle and implement standardized tracking systems.
- Promote adherence to safety protocols for tool usage, storage, and handling.
Facilities Oversight
- Oversee the maintenance and operation of plant infrastructure, including HVAC, electrical, plumbing, and building systems.
- Plan and execute long-term facility maintenance initiatives and capital projects.
- Ensure all systems meet regulatory, environmental, and safety requirements.
- Supervise contractors performing facility upgrades and routine maintenance.
- Respond promptly to facility-related emergencies and maintain a clean, safe work environment.
Team Leadership and Development
- Recruit, train, and manage a multidisciplinary team consisting of maintenance technicians, toolmakers, and facilities staff.
- Foster a culture of safety, accountability, and continuous improvement.
- Conduct regular performance reviews, establish development plans, and facilitate technical training.
- Encourage cross-training and job rotation to build team versatility and operational resilience.
Safety and Compliance
- Promote a safety-first culture and ensure compliance with OSHA regulations and internal safety standards.
- Conduct routine safety inspections and audits; lead investigations into incidents and enforce corrective measures.
- Maintain current safety documentation, procedures, and certifications.
- Oversee implementation of safety protocols, including lockout/tagout, confined space entry, and hazardous materials handling.
Planning and Budget Management
- Develop and oversee annual budgets related to maintenance, tool room operations, and facilities management.
- Monitor expenditures and drive cost savings through efficiency improvements and vendor negotiations.
- Manage spare parts inventory, procurement processes, and usage tracking.
- Lead capital planning efforts for equipment upgrades, replacements, and facility enhancements.
- Solicit, evaluate, and negotiate vendor contracts for outsourced maintenance services.
Continuous Improvement and Reliability Engineering
- Track key maintenance metrics such as Overall Equipment Effectiveness (OEE), Mean Time to Repair (MTTR), and Mean Time Between Failures (MTBF); implement initiatives to improve performance.
- Collaborate with engineering and production teams on equipment modifications and facility layout optimization.
Qualifications:
- Education: Bachelor’s degree in Mechanical, Electrical, or Industrial Engineering preferred; equivalent experience will be considered.
- Experience: Minimum of 10 years in industrial maintenance, including 5+ years in a leadership role; experience in metal fabrication environments is strongly preferred.
Technical Skills:
- In-depth knowledge of mechanical, hydraulic, and electrical systems.
- Skilled in diagnosing and maintaining legacy equipment.
- Proficiency with CMMS and maintenance planning tools.
Leadership Skills:
- Proven ability to lead teams, coach individuals, and resolve conflicts.
- Strong communication and project management skills.
- Experience coordinating cross-functional teams and vendor relationships.
Working Conditions:
- Significant time spent on the production floor within a manufacturing environment.
- Regular exposure to machinery, noise, lubricants, and industrial hazards.