Maintenance Manager
Location: Grand Prairie,TX Company: Qual Pac Customer Site: Frito-Lay (Dedicated Facility) Facility Size: ~250,000 sq ft Operation: 3 shifts | 6 days/week | 3 automated lines + 4 manual lines Position SummaryQual Pac is seeking a highly capable and people-focused Facility Maintenance Manager to lead all maintenance operations at our dedicated Frito-Lay contract packaging facility in Grand Prairie,TX. This role is responsible for both: Facility Maintenance & Infrastructure Automated Packaging Equipment Reliability & Performance The site produces approximately 10 million cases annually of snack variety packs and is transitioning to a high-volume, 3-shift automated operation. The Maintenance Manager will oversee a team of approximately 6 maintenance technicians and ensure maximum uptime, safety compliance, and strong customer partnership performance. This is a hands-on leadership role requiring strong technical expertise, structured maintenance systems management (WMS/PMMS), and excellent team development capabilities. Key ResponsibilitiesMaintenance Leadership & Team DevelopmentLead, coach, and develop a team of ~6 maintenance technicians. Establish clear performance expectations and accountability standards. Build technical capability through structured training and cross-training. Create a culture of safety, ownership, and urgency around equipment reliability. Support 3-shift coverage planning and escalation protocols. Provide escalation support outside normal hours as needed in a 24/6 operation Equipment Reliability & Automation SupportOversee maintenance, troubleshooting, and reliability of: Case erectors Robotic picking systems Case packers Case sealers Robotic palletizers Printers and label systems Scales Date coders Conveyance systems Responsibilities include: Developing and executing Preventive Maintenance (PM) programs Driving predictive maintenance initiatives Root cause analysis (RCA) for recurring failures Reducing unplanned downtime Managing spare parts strategy Supporting line changeovers and automation optimization Serve as primary technical escalation point for complex mechanical, electrical, PLC, and robotic system failures. Personally lead troubleshooting efforts during critical production downtime events Facility & Infrastructure ManagementAlthough this is a Frito-owned facility, Qual Pac holds responsibility for most site-related maintenance, including: Dock doors & levelers Overhead fans Bathrooms & break rooms Ice machines Safety systems General building upkeep AIB readiness & sanitation compliance Lighting & facility infrastructure Ensure the site remains: Audit-ready at all times Compliant with AIB and food safety standards OSHA and safety regulation compliant Safety & Compliance LeadershipChampion equipment safety protocols and LOTO procedures. Ensure all automated systems meet safety standards. Maintain documentation and compliance records. Partner with Safety and Operations teams to eliminate hazards. Conduct safety audits and corrective actions. WMS / PMMS System OwnershipEnsure full utilization of WMS/PMMS system for: Work Orders (WOs) Preventive Maintenance (PMs) Parts inventory control Asset tracking Drive data accuracy and technician adoption. Develop KPI dashboards around: Uptime MTBF / MTTR PM compliance Parts spend Use system data to improve reliability and cost control. Customer Partnership (Frito-Lay)Maintain strong professional working relationship with customer leadership. Respond to facility and equipment needs with urgency. Support customer automation initiatives and expansion efforts. Participate in site reviews and performance discussions. Key Performance Indicators (KPIs)Equipment uptime and OEE improvement PM completion rate (>95%) Reduction in reactive work orders Safety incident reduction AIB audit performance Maintenance cost control Team retention and engagement Required Qualifications5+ years of maintenance leadership experience in manufacturing or packaging. Experience managing automated packaging lines and robotics. Strong mechanical, electrical, pneumatic, and PLC troubleshooting skills. Proven experience implementing or managing a CMMS/PMMS system. Demonstrated ability to lead and develop maintenance technicians. Deep knowledge of equipment safety standards and LOTO compliance. Experience in food or consumer packaged goods (CPG) environment preferred. Strong organizational and communication skills. Preferred QualificationsExperience in contract packaging or high-volume distribution environments. Lean manufacturing or reliability certification (CMRP preferred). Experience supporting multi-shift operations. Prior experience in customer-dedicated facilities. Leadership CompetenciesThe ideal candidate is: A strong people leader, not just a technical expert. Structured and systems-driven. Calm under pressure. Proactive rather than reactive. Customer-focused. Comfortable in a fast-paced, automated environment. Committed to safety and accountability. Set daily maintenance priorities aligned with production demands and make real-time decisions balancing reactive and preventive work. Downtime Ownership & Performance AccountabilityOwn maintenance-driven downtime performance. Partner with Operations to drive OEE improvements. Identify systemic reliability risks and implement long-term corrective strategies.