Technical Maintenance Manager

JOB SUMMARY

The Technical Maintenance Manager is responsible for ensuring optimal performance, availability, and reliability of all production equipment within a cosmetics contract manufacturing environment. This role oversees end-to-end technical floor execution, including equipment setup, production support, cleaning validation, scheduling coordination, SMED optimization, and performance reporting. The position acts as the operational link between production execution, maintenance reliability, engineering, quality, and planning to ensure uninterrupted manufacturing flow and achievement of OEE targets.

DUTIES / RESPONSIBILITIES

• Lead and execute all machine changeovers and pre-production setups
• Verify equipment configuration according to batch records and work orders
• Ensure tooling, change parts, and accessories are correctly installed and validated
• Complete pre-run checklists and first article approvals
• Coordinate setup windows with production planning
• Monitor equipment performance during production runs
• Adjust machine settings to maintain speed, quality, and output targets
• Troubleshoot mechanical issues and minimize downtime
• Track actual vs. planned output and report deviations
• Ensure operators follow correct machine operating procedures
• Perform and document in-process quality checks per batch requirements
• Monitor critical quality attributes (fill weight, seal integrity, labeling, appearance, coding)
• Escalate and isolate non-conforming products when required
• Support QA investigations and batch release requirements
• Lead post-production teardown, cleaning, and sanitization activities
• Ensure compliance with GMP and validated cleaning procedures
• Verify equipment reassembly and readiness for next production cycle
• Document cleaning activities and report equipment issues identified during teardown
• Own and drive SMED initiatives across all production lines
• Conduct time studies and identify internal vs. external setup tasks
• Implement standardized and repeatable changeover procedures
• Train teams on optimized changeover methods
• Track and reduce changeover times continuously
• Build weekly production schedules based on demand, capacity, and material availability
• Assign jobs to optimal production lines based on capability and efficiency
• Integrate setup, run, cleaning, and changeover times into planning
• Adjust schedules in real time based on operational constraints
• Determine optimal equipment routing for each product type and format
• Maintain equipment capability matrix for all production lines
• Resolve routing conflicts and ensure capacity alignment
• Identify equipment limitations impacting production planning
• Establish and validate production run speeds by product and format
• Optimize throughput while maintaining quality standards
• Track and report actual vs. target speeds by line and product
• Identify continuous improvement opportunities for efficiency gains
• Manage departmental budget including labor, consumables, tooling, and maintenance supplies
• Track and report monthly budget variances with corrective actions
• Control overtime through effective scheduling and SMED improvements
• Support capital expenditure requests with cost-benefit analysis
• Act as the primary floor liaison with Maintenance/PRM functions
• Report equipment issues and performance trends in real time
• Coordinate preventive maintenance windows with production schedules
• Support RCA, FMEA, and reliability improvement initiatives
• Jointly drive OEE improvement (availability performance reliability)
• Daily, weekly, and monthly reporting on:
  • Production performance and downtime
  • Changeover and SMED performance
  • Quality metrics and in-process compliance
  • Schedule attainment and efficiency
  • Cleaning compliance and equipment readiness
  • Budget and cost performance
• Present monthly operational performance reviews

EDUCATION

• Bachelor’s degree in mechanical engineering, Industrial Engineering, Manufacturing Engineering, or related technical field (or equivalent experience)

WORK EXPERIENCE

• 5–10 years in manufacturing operations, packaging, or cosmetics/pharma/FMCG environment

• Strong experience in production equipment setup, troubleshooting, and maintenance coordination

• Proven background in SMED, lean manufacturing, or continuous improvement programs