Industrial Maintenance Lead

Position TitleIndustrial Maintenance LeadDepartment: MaintenanceReports To: Maintenance SupervisorPosition SummaryThe Industrial Maintenance Lead is responsible for leading the daily maintenance operations of the manufacturing facility by coordinating preventive maintenance, corrective repairs, equipment reliability, and facility maintenance activities. This position provides technical leadership and direction to the Maintenance Technician team to ensure all production equipment, utilities, and facility systems operate safely, efficiently, and reliably.The Industrial Maintenance Lead serves as the department's technical expert for mechanical, electrical, pneumatic, hydraulic, and control systems. This role coordinates maintenance work orders through the Computerized Maintenance Management System (CMMS), prioritizes reactive and preventive maintenance activities, oversees contractor work, and partners with Production, Engineering, Quality, and the Setup Team to maximize equipment uptime and Overall Equipment Effectiveness (OEE).Unlike the Setup Lead, whose primary responsibility is production line changeovers and equipment setup, the Industrial Maintenance Lead is responsible for maintaining and restoring equipment reliability, reducing equipment failures, improving preventive maintenance programs, and ensuring long-term asset performance.Essential Duties and ResponsibilitiesMaintenance LeadershipLead the daily activities of the Maintenance Department and assign work based on production priorities and equipment needs.Coordinate corrective, preventive, and predictive maintenance activities.Monitor maintenance workloads and adjust priorities to minimize production downtime.Provide technical guidance and support to Maintenance Technicians.Promote a safe, productive, and collaborative work environment.Assist the Maintenance Supervisor with departmental planning and scheduling.Ensure maintenance work is completed safely, efficiently, and according to established standards.Preventive and Predictive MaintenanceCoordinate and schedule preventive maintenance using the CMMS.Review completed preventive maintenance activities for accuracy and completeness.Develop and improve preventive maintenance procedures to increase equipment reliability.Identify recurring equipment failures and implement permanent corrective actions.Support predictive maintenance initiatives including vibration analysis, thermal inspections, lubrication programs, and equipment condition monitoring when applicable.Ensure maintenance schedules minimize production interruptions while maximizing equipment availability.Equipment ReliabilityMaintain and repair manufacturing equipment including but not limited to:Liquid fillersTube fillersBottle unscramblersBottle cappersCap sortersInduction sealersPressure-sensitive labelersShrink sleeve applicatorsCartonersCase packersConveyorsCheckweighersInkjet and laser coding systemsVision inspection systemsPumpsMixersCompressorsFacility support equipmentMechanical and Electrical MaintenanceLead and perform maintenance involving:Mechanical systemsElectrical systemsHydraulic systemsPneumatic systemsVariable Frequency Drives (VFDs)AC and DC motorsMotor controlsSensorsPhoto eyesLoad cellsSolenoid valvesGearboxesBearingsChains and sprocketsConveyorsPLC-controlled equipment (mechanical support and diagnostics)Replace, repair, adjust, calibrate, and test equipment to restore safe and reliable operation.TroubleshootingLead complex troubleshooting activities involving:Mechanical failuresElectrical faultsPneumatic leaksHydraulic failuresMotor failuresConveyor issuesSensor failuresPLC-related equipment faults (coordinate with controls personnel as required)Utility failuresProduction equipment breakdownsPerform Root Cause Analysis (RCA) and develop corrective actions that eliminate recurring failures.CMMS AdministrationUtilize the Computerized Maintenance Management System (CMMS) to:Create work ordersPrioritize maintenance requestsAssign work to techniciansTrack labor hoursRecord repair historyDocument equipment failuresMonitor preventive maintenance complianceMaintain equipment maintenance recordsEnsure all maintenance documentation is accurate and completed in a timely manner.Spare Parts and InventoryMaintain critical spare parts inventory.Recommend inventory levels based on equipment criticality.Submit purchase requisitions for maintenance materials and replacement parts.Work with Purchasing to ensure timely availability of repair components.Maintain organization of the maintenance shop and spare parts storage areas.Contractor CoordinationCoordinate outside contractors performing maintenance, repairs, installations, and capital improvement projects.Verify contractors comply with company safety policies, GMP requirements, and facility procedures.Inspect completed contractor work before acceptance.Continuous ImprovementSupport Lean Manufacturing and equipment reliability initiatives by:Improving preventive maintenance programs.Reducing emergency breakdowns.Increasing equipment uptime.Improving Overall Equipment Effectiveness (OEE).Participating in Root Cause Analysis investigations.Supporting CAPA activities.Assisting Engineering with equipment upgrades and new equipment installations.Developing standardized maintenance procedures.Identifying opportunities to reduce maintenance costs while improving equipment reliability.Safety and Regulatory ComplianceEnsure compliance with:OSHA regulationsLockout/Tagout (LOTO)Good Manufacturing Practices (GMP)Hazard CommunicationElectrical SafetyMachine Guarding requirementsCompany Environmental, Health, and Safety policiesVerify all maintenance work is completed safely before equipment is returned to production.Immediately report unsafe conditions and initiate corrective actions when necessary.Training and LeadershipTrain and mentor Maintenance Technicians on equipment maintenance, troubleshooting, and safe work practices.Provide coaching and technical guidance.Assist with technician competency evaluations.Review employee timecards in the HRIS system.Support employee development through ongoing technical training.Key Performance Indicators (KPIs)Performance will be evaluated based on:Equipment uptimeOverall Equipment Effectiveness (OEE)Mean Time Between Failures (MTBF)Mean Time to Repair (MTTR)Preventive Maintenance complianceWork Order completion rateEmergency maintenance reductionEquipment reliability improvementsMaintenance cost controlSafety performanceContractor performanceDocumentation accuracyRequired Knowledge, Skills, and AbilitiesTechnical SkillsAdvanced knowledge of industrial mechanical, electrical, pneumatic, and hydraulic systems.Experience troubleshooting automated manufacturing equipment.Knowledge of motors, drives, sensors, PLC-controlled equipment, and machine controls.Ability to read electrical schematics, mechanical drawings, and technical manuals.Proficiency using precision measuring tools and diagnostic equipment.Experience operating CMMS software.Leadership SkillsAbility to lead maintenance teams and coordinate multiple repair priorities.Strong organizational and delegation skills.Excellent decision-making abilities.Ability to coach and mentor technicians.Problem SolvingAdvanced troubleshooting skills.Root Cause Analysis (RCA).Failure analysis.Continuous Improvement mindset.CommunicationExcellent verbal and written communication skills.Ability to communicate effectively with Production, Engineering, Quality, Purchasing, contractors, and management.Minimum QualificationsHigh School Diploma or GED required.Associate degree or technical certification in Industrial Maintenance, Mechatronics, Electrical Technology, or a related field preferred.Minimum five (5) years of industrial maintenance experience in a manufacturing environment.Minimum two (2) years of leadership or lead maintenance experience preferred.Experience with automated packaging or filling equipment.Experience using a Computerized Maintenance Management System (CMMS).Working knowledge of OSHA regulations, Lockout/Tagout (LOTO), and Good Manufacturing Practices (GMP).Preferred CertificationsIndustrial Electrical CertificationPLC Troubleshooting TrainingOSHA 30-Hour General IndustryLean ManufacturingSix Sigma Yellow or Green BeltForklift CertificationFirst Aid/CPR CertificationPhysical RequirementsThe employee must regularly:Stand and walk for extended periods.Lift, carry, push, and pull materials weighing up to 50 pounds and occasionally up to 75 pounds.Bend, kneel, crouch, crawl, climb ladders, and work in elevated areas.Perform repetitive hand and wrist movements while using tools.Work safely around energized and moving equipment.Use close vision, distance vision, color vision, peripheral vision, and depth perception.Reasonable accommodations may be made to enable qualified individuals with disabilities to perform the essential functions of the position.Work EnvironmentThis position is performed in a manufacturing environment where employees are regularly exposed to:Moving mechanical equipmentElectrical systemsPneumatic and hydraulic equipmentNoise and vibrationForklift trafficDust, fumes, and airborne particlesTemperature variationsManufacturing chemicals used in accordance with Safety Data Sheets (SDS)Strict compliance with safety procedures, GMP requirements, and environmental regulations is required.Personal Protective Equipment (PPE)Employees are required to wear appropriate PPE, including:Safety glassesHearing protectionCut-resistant glovesHard hat (when required)Steel-toe safety shoesRespiratory protection (when required and medically qualified)Arc flash PPE when performing energized electrical work in accordance with company policy