Chief Mechanic

Department: Maintenance / Production Reports To: Maintenance Manager / Operations Management FLSA Status: Non-Exempt

Position Summary

The Chief Mechanic is responsible for maintaining, troubleshooting, adjusting, setting up, and supporting production and packaging equipment used in a soap manufacturing and industrial production environments. This position works closely with Production, Quality, Safety, and Maintenance personnel to support safe, reliable, and efficient operation of manufacturing lines.

The Chief Mechanic must be able to learn, operate, set up, troubleshoot, and make mechanical adjustments to a wide variety of production and packaging equipment. The position requires strong mechanical aptitude, attention to detail, the ability to diagnose equipment problems, and the ability to respond effectively to production equipment issues.

The Chief Mechanic may operate production equipment as needed to support production, perform changeovers, assist with equipment cleaning and preparation, and make adjustments necessary to maintain continuous production operations.

ESSENTIAL DUTIES AND RESPONSIBILITIES

Equipment Setup and Changeovers

• Set up production and packaging equipment for scheduled production runs and product changeovers.
• Disassemble, remove, and reinstall appropriate machine components as required for equipment cleaning, sanitation, inspection, maintenance, and changeover activities.
• Set up and adjust equipment according to work orders, production requirements, established procedures, and instructions from supervision.
• Ensure equipment is properly adjusted and operational before and during production runs.
• Make mechanical adjustments and fine-tuning to equipment to maintain product quality, equipment performance, and production efficiency.
• Support timely completion of production changeovers while maintaining required safety and quality standards.

Mechanical Troubleshooting and Repair

• Troubleshoot mechanical problems involving production, packaging, conveying, filling, cutting, wrapping, cartoning, and related equipment.
• Identify the likely cause of equipment malfunctions and determine appropriate corrective action.
• Make routine mechanical repairs and adjustments within the scope of the position and employee's training and qualifications.
• Recognize electrical, pneumatic, hydraulic, or other technical issues that require additional expertise and promptly communicate those issues to the appropriate Maintenance or management personnel.
• Assist with more complex repairs and equipment issues as directed.
• Use hand tools, power tools, measuring devices, and other maintenance equipment safely and appropriately.
• Monitor equipment operation and identify conditions that could result in equipment failure, unsafe operation, product defects, or production interruptions.

Preventive Maintenance

• Perform preventive maintenance (PM) activities on assigned production and packaging equipment in accordance with established schedules and procedures.
• Inspect equipment for wear, damage, leaks, loose components, abnormal noise, vibration, or other conditions requiring attention.
• Lubricate, adjust, clean, and replace components as required by established maintenance procedures.
• Document completed maintenance activities and communicate equipment conditions requiring follow-up.
• Assist in identifying recurring equipment problems and recommend opportunities to improve equipment reliability and reduce downtime.

Production Equipment

The Chief Mechanic must develop and maintain working knowledge of production and packaging equipment used throughout the facility, including, as applicable:

• Soap plodders and related soap-processing equipment
• Presses and stamping equipment
• Mixing tanks and associated equipment
• Liquid filling equipment
• Electronic and mechanical cutters
• Chain cutters
• Ink-jet printers/coding equipment
• Wrapping and packaging machines
• Cartoning equipment
• Case packing equipment
• Automatic sealing equipment
• Conveyors and material-handling equipment
• Off-line packaging equipment
• Other production equipment assigned by management

Specific equipment may include STUH, STUF, STU-S, STHV, Condor presses, Doboy wrappers, BFB wrappers, Scandia wrappers, Acme 711/731 wrappers, Marden Edwards wrappers, CE-75 cello wrappers, PL75 pleat wrappers, Auto "L" sealers, cartoning machines, 4000T equipment, and similar machinery. Equivalent equipment experience may be considered.

The employee is expected to learn additional equipment and processes as required by the operation.

Safety, Quality, and GMP

• Follow all company safety policies, OSHA requirements, machine-safety procedures, lockout/tagout requirements, and applicable environmental, health, and safety practices.
• Properly use required personal protective equipment (PPE).
• Follow applicable Good Manufacturing Practices (GMP), quality procedures, housekeeping standards, and product-protection requirements.
• Maintain equipment and work areas in a clean, orderly, and safe condition.
• Immediately report unsafe equipment conditions, damaged guards, safety hazards, spills, leaks, or other conditions that could present a risk to employees, products, equipment, or the facility.
• Do not bypass, remove, disable, or defeat machine guards, safety devices, interlocks, or other protective equipment except as specifically authorized under approved maintenance procedures.
• Follow appropriate lockout/tagout and energy-control procedures when servicing equipment.
• Maintain awareness of exposure risks associated with soaps, chemicals, fragrances, dust, heat, noise, and other manufacturing conditions and use required controls and PPE.

Communication and Production Support

• Communicate equipment problems, production interruptions, maintenance needs, and safety concerns promptly to the appropriate supervisor or Maintenance/Operations management.
• Work cooperatively with Production, Quality, Safety, Warehouse, and other departments.
• Assist supervisors and other maintenance/support personnel as needed.
• Provide assistance during equipment startups, shutdowns, changeovers, troubleshooting, and production interruptions.
• Provide information regarding recurring equipment problems and recommended maintenance needs.
• Perform other related duties as assigned.

REQUIRED KNOWLEDGE, SKILLS, AND ABILITIES

• Strong mechanical aptitude and troubleshooting skills.
• Ability to read and follow equipment setup instructions, work orders, maintenance procedures, and other written instructions.
• Ability to use common hand tools, power tools, and measuring instruments.
• Basic understanding of mechanical systems, bearings, belts, chains, sprockets, gears, shafts, drives, motors, pumps, and related components.
• Ability to learn and troubleshoot automated production and packaging equipment.
• Basic electrical knowledge is preferred; experience with industrial electrical systems, controls, sensors, motors, and troubleshooting is a plus.
• Basic knowledge of pneumatic and hydraulic systems is preferred.
• Ability to identify equipment problems and determine when additional technical assistance is required.
• Ability to work effectively under production time constraints while maintaining safety and quality requirements.
• Ability to communicate clearly with supervisors, coworkers, and other departments.
• Ability to work independently with appropriate direction and prioritize multiple maintenance and production-support needs.

EDUCATION AND EXPERIENCE

• High school diploma or GED required, or equivalent combination of education and relevant industrial experience.
• Prior experience in industrial manufacturing, maintenance, mechanical repair, production equipment setup, or a related field preferred.
• Experience in soap, chemical, consumer products, packaging, food, pharmaceutical, or other process/manufacturing environments is preferred.
• Demonstrated mechanical troubleshooting and equipment setup experience required.
• Electrical, pneumatic, hydraulic, welding, fabrication, or industrial maintenance experience is a plus.
• Equivalent combinations of education, training, and experience may be considered.

PHYSICAL REQUIREMENTS

The physical requirements described below represent the general physical capabilities needed to perform the essential functions of the position. Reasonable accommodations may be considered for qualified individuals with disabilities.

• Ability to stand and walk for extended periods during the work shift.
• Ability to frequently bend, stoop, kneel, crouch, reach, climb, and work in varying positions around manufacturing equipment.
• Ability to safely lift, carry, push, and pull materials, tools, equipment components, and other items associated with the job, with heavier or awkward loads handled using appropriate assistance or mechanical lifting equipment.
• Ability to use hands and arms for frequent handling of tools and equipment.
• Ability to work around operating manufacturing machinery, moving equipment, elevated temperatures, noise, dust, chemicals, soaps, fragrances, and other typical manufacturing conditions.
• Ability to wear required PPE, which may include safety glasses, gloves, hearing protection, protective clothing, safety footwear, respiratory protection, or other equipment as required by the job and applicable safety assessments.
• Ability to safely perform the essential functions of the position with or without reasonable accommodation.