Maintenance Manager
10 days ago
Grand Prairie
Job Description Location: Grand Prairie,TX Company: Qual Pac Customer Site: Frito-Lay (Dedicated Facility) Facility Size: ~250,000 sq ft Operation: 3 shifts | 6 days/week | 3 automated lines + 4 manual lines Position Summary Qual Pac is seeking a highly capable and people-focused Facility Maintenance Manager to lead all maintenance operations at our dedicated Frito-Lay contract packaging facility in Grand Prairie,TX. This role is responsible for both: • Facility Maintenance & Infrastructure This is a hands-on leadership role requiring strong technical expertise, structured maintenance systems management (WMS/PMMS), and excellent team development capabilities. Key Responsibilities1. Maintenance Leadership & Team Development • Lead, coach, and develop a team of ~6 maintenance technicians., • Establish clear performance expectations and accountability standards., • Build technical capability through structured training and cross-training., • Create a culture of safety, ownership, and urgency around equipment reliability., • Support 3-shift coverage planning and escalation protocols., • Case erectors, • Robotic picking systems, • Case packers, • Case sealers, • Robotic palletizers, • Printers and label systems, • Scales, • Date coders, • Developing and executing Preventive Maintenance (PM) programs, • Driving predictive maintenance initiatives, • Root cause analysis (RCA) for recurring failures, • Reducing unplanned downtime, • Managing spare parts strategy, • Supporting line changeovers and automation optimization, • Serve as primary technical escalation point for complex mechanical, electrical, PLC, and robotic system failures., • Dock doors & levelers, • Overhead fans, • Bathrooms & break rooms, • Ice machines, • Safety systems, • General building upkeep, • AIB readiness & sanitation compliance, • Audit-ready at all times, • Compliant with AIB and food safety standards, • OSHA and safety regulation compliant4. Safety & Compliance Leadership, • Champion equipment safety protocols and LOTO procedures., • Ensure all automated systems meet safety standards., • Maintain documentation and compliance records., • Partner with Safety and Operations teams to eliminate hazards., • Conduct safety audits and corrective actions.5. WMS / PMMS System Ownership, • Ensure full utilization of WMS/PMMS system for:, • Work Orders (WOs), • Preventive Maintenance (PMs), • Parts inventory control, • Asset tracking, • Drive data accuracy and technician adoption., • Develop KPI dashboards around:, • Uptime, • MTBF / MTTR, • PM compliance, • Parts spend, • Use system data to improve reliability and cost control.6. Customer Partnership (Frito-Lay), • Maintain strong professional working relationship with customer leadership., • Respond to facility and equipment needs with urgency., • Support customer automation initiatives and expansion efforts., • Participate in site reviews and performance discussions.Key Performance Indicators (KPIs), • Equipment uptime and OEE improvement, • PM completion rate (>95%), • Reduction in reactive work orders, • Safety incident reduction, • AIB audit performance, • Maintenance cost control, • Team retention and engagementRequired Qualifications, • 5+ years of maintenance leadership experience in manufacturing or packaging., • Experience managing automated packaging lines and robotics., • Strong mechanical, electrical, pneumatic, and PLC troubleshooting skills., • Proven experience implementing or managing a CMMS/PMMS system., • Demonstrated ability to lead and develop maintenance technicians., • Deep knowledge of equipment safety standards and LOTO compliance., • Experience in food or consumer packaged goods (CPG) environment preferred., • Strong organizational and communication skills.Preferred Qualifications, • Experience in contract packaging or high-volume distribution environments., • Lean manufacturing or reliability certification (CMRP preferred)., • Experience supporting multi-shift operations., • A strong people leader, not just a technical expert., • Structured and systems-driven., • Calm under pressure., • Proactive rather than reactive., • Customer-focused., • Comfortable in a fast-paced, automated environment., • Committed to safety and accountability., • Set daily maintenance priorities aligned with production demands and make real-time decisions balancing reactive and preventive work.Downtime Ownership & Performance Accountability, • Own maintenance-driven downtime performance., • Partner with Operations to drive OEE improvements., • Identify systemic reliability risks and implement long-term corrective strategies.