Preventive & Reliability Manager

JOB SUMMARY

Responsible for maximizing equipment uptime, asset reliability, and production continuity through the development and execution of robust preventive and predictive maintenance programs and reliability engineering practices. In a cosmetics contract manufacturing environment, this role partners closely with the Floor Maintenance Manager (FMM) to align strategic maintenance planning with real-time production floor execution, ensuring equipment reliability supports safety, quality, and customer delivery commitments.

DUTIES / RESPONSIBILITIES

• Own, develop, and continuously improve the plant-wide preventive maintenance master schedule for all equipment and utilities
• Define PM frequencies using OEM recommendations, equipment history, and criticality analysis
• Maintain ≥95% PM compliance and ensure accurate tracking within the CMMS
• Review and optimize PM task content, labor standards, and spare parts requirements
• Coordinate PM windows with the Floor Maintenance Manager to minimize production disruption
• Incorporate floor-level feedback, teardown findings, and post-run observations into PM strategy updates
• Lead Root Cause Analysis (RCA) and Failure Mode & Effects Analysis (FMEA) for critical and recurring failures
• Drive permanent corrective actions and ensure timely closure of reliability issues
• Monitor and improve MTBF and MTTR performance metrics
• Eliminate repeat failures through engineering-based long-term solutions
• Use downtime data and technician feedback from the FMM as key inputs into reliability investigations
• Conduct joint reliability reviews with the FMM to proactively identify failure trends
• Coordinate predictive maintenance inspections with production schedules in partnership with the FMM
• Ensure equipment access is aligned with setup, changeover, or post-production windows
• Implement condition-based monitoring strategies to reduce unplanned downtime
• Define and manage critical spare parts lists based on equipment risk and failure history
• Collaborate with Procurement on lead times, vendor management, and cost optimization
• Prevent stockouts of critical components while controlling inventory carrying costs
• Align spare parts strategy with FMM-managed production change parts to eliminate duplication
• Adjust inventory proactively using teardown reports and wear pattern analysis
• Maintain and continuously update an asset criticality register (A/B/C or 1/2/3 ranking system)
• Prioritize maintenance activities based on operational and production risk
• Support capital planning and end-of-life asset replacement decisions
• Incorporate FMM operational feedback (performance, setup challenges, sanitization equipment condition) into criticality assessments
• Ensure sanitization room assets are fully integrated into the reliability strategy
• Own the preventive maintenance and reliability budget
• Forecast, track, and control maintenance spending
• Justify capital expenditures tied to reliability improvements and risk reduction
• Track cost savings and cost avoidance resulting from reliability initiatives
• Partner with the Floor Maintenance Manager as the primary interface for all floor equipment reliability matters
• Work with Engineering on new equipment installations, commissioning, and maintainability design reviews
• Support Quality and Regulatory teams during equipment qualification (IQ/OQ/PQ) and change control
• Coordinate with EHS to ensure safe maintenance practices (LOTO, confined space, etc.)
• Align PM execution with Planning & Scheduling to support production requirements
• Manage OEMs, contractors, calibration vendors, and specialized maintenance providers
• Ensure compliance with GMP, safety, and quality standards
• Evaluate contractor performance and control service costs
• Coordinate contractor access with the FMM to avoid production conflicts and ensure safe equipment handoff
• Maintain daily collaboration with the FMM as the primary source of real-time equipment intelligence
• Respond to CMMS-reported deficiencies with defined prioritization and timely feedback (≤24 hours acknowledgment)
• Jointly review production schedules to align PM, PdM, and corrective work windows
• Collaborate on SMED and equipment modification initiatives to improve maintainability and setup efficiency
• Participate in daily/weekly performance reviews covering downtime, reliability trends, and equipment health
• Share advance notice of maintenance activities impacting production schedules
• Co-own OEE: PRM drives availability and reliability; FMM drives performance and quality
• Conduct formal monthly performance and reliability reviews with the FMM
• Support audit readiness for internal, customer, and regulatory inspections
• Jointly escalate risks impacting production output, quality, or customer commitments
• Report monthly on OEE, PM compliance, MTBF, MTTR, backlog, and maintenance cost performance
• Lead and support Lean, TPM, and reliability improvement initiatives
• Promote operator-led autonomous maintenance and basic care practices in partnership with the FMM
• Translate FMM operational insights into targeted reliability improvement projects
• Drive initiatives supporting faster changeovers, improved sanitation equipment reliability, and reduced downtime

EDUCATION

• Bachelor’s degree in mechanical engineering, Electrical Engineering, Industrial Engineering, or related technical field required

• Master’s degree in engineering, Operations Management, or Reliability Engineering preferred

• Certifications such as CMRP (Certified Maintenance & Reliability Professional), Lean Six Sigma (Green or Black Belt), or TPM certification strongly preferred

• Additional training in GMP environments or regulated manufacturing (cosmetics, pharma, food) is a plus

WORK EXPERIENCE

• 7–10 years of progressive experience in maintenance, reliability engineering, or plant engineering roles

• Minimum 3–5 years in a leadership or managerial role within a manufacturing environment

• Experience in cosmetics, personal care, pharmaceutical, or other regulated FMCG manufacturing environments strongly preferred

• Proven track record in:

• Preventive maintenance program development and execution

• Root Cause Analysis (RCA) and failure reduction initiatives

• CMMS system management and data-driven maintenance strategies

• OEE improvement and downtime reduction

• Experience working in high-speed production environments with complex packaging, filling, or process equipment preferred

• Demonstrated experience managing cross-functional collaboration with production, quality, engineering, and maintenance teams

Salary : $80,000 - $90,000