Maintenance Manager

Position:

Maintenance Manager Location:

Theodore, AL Reports To:

Director of Operations Classification:

Full-Time, Exempt Direct Reports:

11 (Maintenance Foreman, Parts and Inventory, Maintenance and E&I Technicians, Millwrights ) Position Overview INCOA Performance Minerals is seeking a high-caliber, hands-on, and solution-oriented Maintenance Manager to lead our maintenance and reliability team during a critical phase of growth. Having successfully transitioned out of our early start-up phase, we are moving rapidly toward full operational structure and maximum profitability. In this role, you will be the chief architect of our maintenance strategy, transforming our facility from a reactive "break-fix" culture into a highly disciplined, proactive, and predictive operating environment. You will inherit a hardworking team and will be responsible for raising their professional standards, developing their technical capabilities, and aligning their daily habits with lean manufacturing principles. Our facility processes calcium carbonate down to precise, sub-micron specifications utilizing milling, classification, and packaging equipment. If you are an experienced leader who thrives on building structure out of chaos, implementing TPM, and driving direct profitability through equipment reliability, we want you on our leadership team. Key Responsibilities 1. Leadership, Culture & Team Development (Critical Focus)

Manage and Mentor:

Direct, coach, and elevate the existing team members, shifting their mindset from reactive troubleshooting to proactive maintenance.

Standardize Professionalism:

Establish clear accountability, safety compliance, dress code, cell phone policies, and professional behavior on the maintenance floor.

Skill Mapping & Training:

Evaluate the individual strengths of the current team, identify technical gaps, and implement structured training programs (cross-training mechanical, electrical, and instrumentation skills).

Work Order Discipline:

Enforce strict utilization of our CMMS (Computerized Maintenance Management System) to log, track, and complete all work orders, ensuring zero unrecorded maintenance is performed. 2. Transition to Preventative & Predictive Maintenance (PM/PdM)

Eradicate Reactive Downtime:

Shift the plant's maintenance ratio from 80% reactive / 20% proactive to an industry-standard 80% proactive / 20% reactive footprint.

Develop PM Programs:

Design, execute, and continually optimize structured preventative and predictive maintenance schedules for key industrial assets (ball mills, classifiers, packaging lines, pneumatic conveying systems, compressors, and rotary valves).

Critical Spare Parts Management:

Reorganize and manage the spare parts warehouse. Establish strict inventory controls, min/max stocking levels, and critical spares strategies to minimize lead-time bottlenecks. 3. Lean Manufacturing & Continuous Improvement Implement Total Productive Maintenance (TPM): Collaborate with production supervisors to build autonomous maintenance checklists, empowering operators to perform basic clean/inspect/lubricate (CIL) tasks. Root Cause Analysis (RCA): Champion structured problem-solving (5-Whys, Fishbone diagrams) to investigate mechanical failures. Implement permanent engineering or procedural solutions rather than temporary "band-aid" fixes. Workplace Organization (5S): Design and enforce 5S standards across the maintenance shop and tool storage areas, ensuring a clean, safe, and highly efficient working environment. 4.

Cost Control & Profitability Alignment OEE Maximization:

Directly impact the plant's bottom line by increasing Overall Equipment Effectiveness (OEE) and reducing unscheduled downtime during this critical path to profitability.

Budget Management:

Formulate, track, and manage the annual maintenance budget (labor, parts, and contractor services), ensuring maximum ROI on every dollar spent.

Contractor Management:

Oversee external contractors and specialty technicians, ensuring they adhere to INCOA's strict safety standards, deadlines, and cost constraints.

Required Qualifications & Experience Educational Background:

Bachelor's degree in Mechanical Engineering, Electrical Engineering, Industrial Management, or a related field is preferred. Equivalent hands-on technical leadership experience will be strongly considered.

Experience Level:

5+ years of progressive maintenance leadership experience in a heavy industrial manufacturing environment (minerals processing, chemical processing, mining, cement, pulp & paper, or bulk material handling).

Lean Manufacturing Expertise:

Proven, hands-on experience implementing Lean tools such as TPM, 5S, Value Stream Mapping, and Root Cause Analysis. Six Sigma Green or Black Belt is a major plus.

Technical Proficiency:

Deep understanding of heavy rotating equipment, milling operations, pneumatics, hydraulics, bulk packaging automation, PLCs, and electrical distribution systems.

CMMS Mastery:

Strong experience selecting, implementing, or optimizing a Computerized Maintenance Management System (e.g., eMaint, Fiix, SAP, Maximo).

Proven People Manager:

A track record of successfully managing, professionalizing, and developing a team of 10+ blue-collar technicians. Experience managing former peers is highly valued. Key Competencies for

Success Solution-Oriented Mindset:

You do not just report problems; you present concrete, structured solutions with cost-benefit analyses.

Decisive & Disciplined:

You hold yourself and your team to the highest standards of safety, quality, and punctuality.

Exceptional Communicator:

Ability to explain complex technical issues to executive leadership while maintaining a highly respectful, direct, and motivating presence with technicians on the shop floor.

Resilient Under Pressure:

Calm under the pressure of a continuous 24/7 manufacturing schedule, with a relentless focus on solving issues permanently.

Pay:

$95,000.00 - $105,000.00 per year

Benefits:

401(k) 401(k) matching Dental insurance Health insurance Life insurance Paid time off Vision insurance

Work Location:

In person