CapEX Reliability & Maintenance Manager II – Charlotte, NC 

Competitive salary based on knowledge and experience plus annual bonus. Your benefits start on your first day!

Basic Function: 

The CapEx Reliability and Maintenance Manager II is responsible for increasing asset availability to operate at the designed production rates, producing the quality product required with minimal disruption at optimal costs through the utilization of ARP reliability tools and methods. Manage programs to improve equipment reliability, optimize maintenance costs, and reduce equipment downtime. Responsible through the ARP function to maximize maintenance workforce efficiency. Responsible for major outage planning processes and execution to minimize downtime and ensure all maintenance performance will achieve equipment reliability. Due to the nature of manufacturing operations the incumbent may be required to be on-call, and must be available for specific operations or projects.

The CapEx Reliability and Maintenance Manager II is a member of the Mill’s leadership team and reports directly to the Vice President & General Manager. This position is considered a peer to the Melt Shop and Rolling Mill Superintendents, who must work as a team to achieve the optimal production output. The Reliability and Maintenance Manager I regularly interfaces and coordinates reliability and maintenance strategies and improvements with Director Asset Reliability and Maintenance.

This position requires a broad based thought process and substantial experience to:

•      Develop and adjust the complex technical installations of the mill to meet actual and future needs;

•      Adjust and improve the organization and the efficiency of maintenance and reliability activities and teams;

•      Consider the needs of, direct, motivate and develop a large and diverse employee group.

•      Manage individual team performance through the People Management processes and guidelines.

Because of the high value of the capital invested in the mills, long-term planning is of great importance to meet long-term goals while also accommodating current and short-term needs.

The incumbent is accountable for a sound and effective use of ARP reliability tools, methods and practices to increase asset availability and to ensure continuous operation of production facilities, buildings and equipment, as well as minimizing maintenance delays. The incumbent recommends and approves changes and improvements on existing machinery and equipment and directs the repairing and maintaining of plant machinery, equipment, tools, and facilities to prolong plant equipment life; attempting to minimize replacement expense and downtime. The incumbent directs the moving, rearranging, and installation of all plant equipment, machinery, and utility services through subordinate personnel.

The CapEx Reliability and Maintenance Manager II verifies all work in progress as required to ensure that proper maintenance is being performed. Utilizes staff of Reliability Engineers, ARP Planners and support functions to identify and recommend process or equipment changes. The incumbent also anticipates and investigates major production delays and breakdowns to ensure that adequate preventive maintenance is being performed, as well as to investigate delays and to research and recommend major changes to eliminate or minimize delays, safety hazards and downtime; takes necessary corrective action within limits of established policies. The incumbent refers unusual conditions and situations to the Vice President & General Manager and/or operating superintendents for input and concurrence on decisions.

The CapEx Reliability and Maintenance Manager II works in close association with the appropriate personnel to ensure adherence to OSHA regulations and to provide a safe work environment for Gerdau employees.

Working closely with operation and engineering management, the Reliability and Maintenance Manager I is responsible, through subordinate personnel, for conducting evaluations of proposed projects that entail the evaluation and benefits derived from the project. In addition, this position has responsibility to support the preliminary project preparation and expenditure authorization reports for the Vice President & General Manager's approval and submission through the Corporate approval process. Coordinates the procurement of maintenance/repair parts (MRO), supplies and materials through the Procurement department. Responsible for monitoring to ensure maintenance parts inventory are maintained at appropriate minimum/maximum levels. The incumbent will evaluate vendor proposals along with operating personnel and serve as an active participant in the vendor selection process. Annually prepare capital expenditure budget including extraordinary maintenance item expense proposals.

The incumbent is responsible for the supervision of the Mill Shared/Central maintenance, Asset Reliability, Maintenance Support functions, and Central Automation Team. Interacts regularly with maintenance staff and acts as catalyst to facilitate exchange of ideas, sharing/use of best practices and to attack significant maintenance problems. Responsible for clearly defining problems, developing alternate solutions, gaining concurrence of operating management and implementing solutions to either eliminate recurring or significant equipment reliability and/or safety problems.

The CapEx Reliability and Maintenance Manager II will ensure maintenance manuals, standard maintenance operating procedures, CMMS, equipment reliability databases and other maintenance related software systems are properly maintained. The incumbent is responsible for the hiring, development and deployment of all maintenance personnel, oversight of training programs for maintenance and operations regarding equipment testing, operation and repair, new software, methodologies and procedures. This position requires the ability to effectively communicate with associates at all levels within the organization.

The CapEx Reliability and Maintenance Manager II works in close cooperation and communication with the other department superintendents, providing support staff services for the operating departments to ensure that proper maintenance functions are performed with minimum delay and at the optimal cost.

The primary challenge for this position is to safely minimize production delays due to equipment or facility malfunctions, while balancing job duties with cost goals.

The incumbent reviews all salary, position changes, disciplinary and performance appraisal actions initiated by subordinate supervisors/facilitators and all maintenance personnel. Must be well-versed in training and leadership techniques since the incumbent may provide on-the-job training and guidance to subordinate supervisors/facilitators and hourly personnel. Accountable for employee compliance with established safety procedures and policies.

Your Work: 

Principal Accountabilities:

• Lead the total maintenance and reliability effort at the Mill with direct supervisory responsibility for Asset Reliability Process, shared/central maintenance and maintenance support group at the Mill.
• Administer all Gerdau Maintenance Shop policies and practices related to employees; maintain effective control in resolving employee grievances; coordinate and track teambuilding efforts.
• Manages major recommendations as to modifications, renovations, installations, additions and replacements of facilities and equipment.
• Manages the Engineering, Reliability, Maintenance, and Automation Areas, selecting and training employees, and conducting performance appraisals.
• Manages the preparation of the construction project budget, scheduling and approving expenditures, analyzing variances and initiating corrective action when necessary, including process data analysis, problem solving, root cause analysis, failure mode, and fact-cause-effect analysis.
• Controls expenditures within limitations of the location’s entire capital expense budget.
• Coordinates the interacting with outside contractors and vendors as required by project needs and for drafting and negotiating contracts with vendors, and establishing the performance criteria for each contract drafted.
• Cooperate and coordinate with other department leaders to ensure efficient and effective maintenance efforts. Maintain open communications channels.
• Participate in ARP assessments and manage internal ARP assessments to evaluate ARP practice effectiveness and develop and execute improvement plans.
• Collaborate with operations, maintenance, engineering, reliability personnel and suppliers to ensure the reliability of equipment on all existing and new assets.
• Conduct routine safety and ARP activities including inspections, audits, visibility tours, and interact with employees and contractors
• Champion the use of Predictive Maintenance (PdM) techniques and other ARP tools to maximize equipment life and performance.
• Manage the Failure Analysis process for maintenance issues.
• Identify skill/knowledge gaps and execute skill development actions for site reliability and maintenance personnel and contractors to support achievement of ARP, maintenance, safety and productivity goals.
• Manage and develop ARP and Maintenance personnel by establishing career goals, providing coaching, and measuring performance.
• Lead the Annual Action Planning process for Total Maintenance including Asset Reliability.
• Implement culture change driving continuous improvement in service and cost, change personnel assessment culture, introduce resource planning concept, identify and eliminate non-value-added tasks.
• Create a rewarding and innovative environment that motivates people to use their talents and energies to the fullest extent possible; develop employees for acceptance of empowerment and career advancement.
• Act as a proactive member of the site leadership team to develop plans and obtain support to achieve World Class performance using Asset Reliability Process.
• Perform other duties and responsibilities as assigned.