Senior Director, Maintenance & Reliability

Full-time - Mid Level

Monroe, NC

Computer and Electronic Product Manufacturing

About the position

The Reliability and Maintenance Manufacturing Lead is responsible for ensuring the integrity, reliability, and safety of critical assets within the manufacturing environment. This role involves developing and implementing asset integrity management programs that drive operational excellence, reduce risk, and maximize asset life, while collaborating with cross-functional teams to meet production, safety, and regulatory standards.

Responsibilities

• Develop and manage a comprehensive Asset Integrity Management System (AIMS) tailored to ATl's advanced manufacturing environment.
• Set standards and guidelines for maintaining the structural and operational integrity of key assets.
• Implement strategies for asset optimization, ensuring maximum availability and minimizing operational disruptions.
• Utilize advanced analytical tools and methodologies to assess the reliability and performance of manufacturing equipment and processes.
• Develop Project Charters for maintenance-related capital funding requests.
• Conduct cost/benefit analysis for improvements to processes and/or equipment.
• Propose different solutions outside of set parameters to address complicated manufacturing equipment issues.
• Lead the inspection and monitoring of assets using advanced technologies like non-destructive testing (NDT), ultrasound, and corrosion monitoring.
• Perform failure analysis on process equipment to determine corrective actions to prevent failures and extend equipment life.
• Oversee condition monitoring efforts to identify and address potential integrity issues before they impact production.
• Conduct root cause analysis (RCA) and failure mode and effects analysis (FMEA) to understand failures and implement corrective actions.
• Perform risk-based inspections (RBI) and fitness-for-service (FFS) assessments to prioritize assets needing attention.
• Implement predictive maintenance programs leveraging data analytics, condition monitoring techniques, and sensor technologies.
• Collaborate with the maintenance team to develop preventive and corrective maintenance schedules.
• Manage shutdowns, overhauls, and repairs for critical production assets.
• Ensure all asset integrity activities comply with industry standards such as ASME, API, and internal safety regulations.
• Maintain accurate records of reliability assessments, maintenance activities, and equipment performance metrics.
• Prepare reports and presentations summarizing key findings, recommendations, and performance trends for management review.
• Lead the implementation of emerging technologies such as digital twins and IoT based predictive maintenance systems.
• Lead a cross-functional team of integrity engineers, inspectors, and maintenance personnel.

Requirements

• Experience in developing and managing asset integrity management systems in a manufacturing environment.
• Strong knowledge of reliability engineering principles and methodologies.
• Proficiency in advanced analytical tools and methodologies for equipment performance assessment.
• Experience with project management and capital funding requests.
• Ability to conduct cost/benefit analysis for process improvements.
• Expertise in non-destructive testing (NDT) and condition monitoring techniques.
• Familiarity with root cause analysis (RCA) and failure mode and effects analysis (FMEA).
• Knowledge of risk-based inspection (RBI) and fitness-for-service (FFS) methodologies.
• Understanding of regulatory compliance standards such as ASME and API.

Nice-to-haves

• Experience with digital twins and IoT based predictive maintenance systems.
• Familiarity with pressure vessel codes and pipeline integrity standards.
• Experience in training and developing teams in asset integrity best practices.

Benefits

• Health insurance
• 401k retirement plan
• Paid holidays
• Professional development opportunities
• Flexible scheduling