Senior Maintenance Engineer

Role Overview

The Senior Maintenance Engineer is responsible for leading equipment reliability, maintenance optimization, and continuous improvement initiatives within a highly automated automotive manufacturing environment. This role provides technical leadership for maintenance operations, drives efforts to improve equipment uptime and performance, supports capital and automation projects, and develops long-term maintenance strategies to support production goals. The Senior Maintenance Engineer works closely with Production, Quality, Engineering, and Maintenance teams to reduce downtime, improve efficiency, and ensure safe, reliable operation of manufacturing equipment.

KEY RESPONSIBILITIES (To perform within this position successfully, the incumbent must be able to perform each essential duty satisfactorily. Other duties may be assigned.)

• Lead equipment reliability and maintenance improvement initiatives to maximize production uptime and operational efficiency.
• Analyze recurring equipment failures and conduct advanced root cause investigations to identify and implement permanent corrective actions.
• Develop, implement, and continuously improve preventive and predictive maintenance programs.
• Monitor maintenance KPIs including equipment uptime, downtime, MTTR, MTBF, and maintenance costs.
• Provide technical leadership and guidance to Maintenance Engineers, Maintenance Supervisors, and Maintenance Technicians.
• Lead troubleshooting efforts involving mechanical, electrical, pneumatic, hydraulic, robotic, and automated manufacturing systems.
• Support installation, commissioning, startup, and validation of new equipment, production lines, and automation systems.
• Evaluate equipment performance and recommend upgrades, modifications, and capital improvements.
• Collaborate with cross-functional teams to improve equipment reliability, process stability, and manufacturing performance.
• Support spare parts strategy development and critical inventory management.
• Lead continuous improvement initiatives utilizing Lean Manufacturing, TPM, Root Cause Analysis, and other reliability methodologies.
• Coordinate activities with equipment manufacturers, vendors, and service providers.
• Develop and maintain maintenance standards, procedures, technical documentation, and equipment specifications.
• Participate in Gemba walks, maintenance audits, and risk assessments to identify improvement opportunities.
• Ensure compliance with safety, environmental, and quality requirements.
• Support budgeting and planning activities for maintenance projects and capital expenditures.
• Perform other duties as assigned.

AUTHORITY & SCOPE This role operates within defined corporate policies and procedures and exercises judgment appropriate to its level of responsibility. The position may influence decisions related to functional operations, processes, or recommendations and escalate matters as required

Qualifications (The requirements listed below are representative of the knowledge, skills, and/or ability required and preferred for this position.)

Required Education & Experience:

• Bachelor's degree in mechanical engineering, Electrical Engineering, Mechatronics Engineering, Industrial Engineering, or a related engineering field
• 5 years of experience in industrial maintenance, reliability engineering, maintenance engineering, or manufacturing engineering.
• Experience leading maintenance improvement initiatives in a manufacturing environment.
• Experience troubleshooting and supporting automated manufacturing equipment.

Required Knowledge, Skills, & Abilities:

• Strong knowledge of equipment reliability, maintenance systems, and manufacturing operations.
• Advanced troubleshooting and root cause analysis skills.
• Strong understanding of mechanical, electrical, hydraulic, pneumatic, and automation systems.
• Ability to interpret engineering drawings, schematics, technical manuals, and equipment documentation.
• Experience analyzing maintenance and equipment performance data.
• Proficiency in Microsoft Excel and Microsoft Office applications.
• Strong project management and organizational skills.
• Excellent communication and leadership abilities.
• Ability to manage multiple priorities in a fast-paced manufacturing environment.
• Knowledge of preventive, predictive, and reliability-centered maintenance practices.

Preferred Education & Experience:

• Experience in automotive manufacturing.
• Experience supporting robotics, PLC-controlled equipment, automated assembly systems, and conveyor systems.
• Experience with CMMS software and maintenance planning systems.
• Knowledge of TPM (Total Productive Maintenance), Lean Manufacturing, and continuous improvement methodologies.
• Experience leading capital projects, equipment installations, and automation initiatives.
• Familiarity with industrial safety standards, machine guarding, and lockout/tagout procedures.

Working Conditions:

• Office and manufacturing plant environment with frequent walking throughout the production floor.
• Exposure to manufacturing equipment, forklifts, and automated systems.
• Ability to wear required PPE while working in production areas.
• Overtime as needed.