Senior Manager Maintenance

Job Description

JOB PURPOSE

The Senior Manager, Maintenance leads a team of IPT Maintenance Leads, Engineers and Technicians to provide leadership and technical expertise for all equipment-related activities in the manufacturing process. The incumbent:

• Supports Director, Operations to meet Profit Plan targets, optimize IPT cost effectiveness, and lower product standard cost in accordance with cGMP practices and safety guidelines, with particular emphasis on equipment maintenance costs.

• Provides expert technical oversight in troubleshooting of equipment issues and breakdowns.

• Implements an effective preventive maintenance program.

• Works with IPT Process Lead and E&SHE CoE to establish and execute a reliability-centered maintenance program.

• Works with other IPT maintenance leads and E&SHE CoE within a Community of Practice to ensure consistent approaches across the site, effective site-wide resolution of atypical and audit findings, and sharing of best practices.

• Maintains the equipment critical spare parts list and ensures availability of spares for  all IPT equipment.

• Coaches Maintenance Leads/Engineers in deviation and atypical investigations, and ensures effective root cause analysis.

• Supports equipment change control implementations.

MAIN RESPONSBILITIES

Manufacturing Excellence

Corrective Maintenance

• Participates in daily IPT walk-through and leads resolution of all identified facility-related equipment issues, unplanned events, and new opportunities with agility and flexibility.

• Prioritizes Engineer and Technician workload on a daily basis and ensures that assigned follow-ups are completed on time.

• Provides technical expertise and support to IPT Maintenance Leads/Engineers/Technicians for equipment breakdown troubleshooting and recovery to ensure timely and effective resolution of issues.

Preventive Maintenance

• Works with E&SHE CoE to develop and implement a reliability-centered maintenance plan to share best practices and lessons learned, with objective of improving asset utilization.

• Liaises with IPT Production Facilitator on equipment availability and vendors to ensure all planned internal and external Preventive Maintenance activities are scheduled and completed.

Equipment Reliability

• Liaises with IPT Process Lead and E&SHE CoE to implement reliability-centered maintenance activities and programs.

• Liaises with E&SHE COE to monitor equipment and maintenance-related metrics and ensures equipment downtime does not exceed capacity planning assumptions.

Equipment Critical Spares

• Maintains the critical equipment spare part list and sets minimum re-order levels to ensure availability.

Incident, Deviation, and Atypical Investigations

• Coaches IPT Maintenance Leads/Engineers to provide equipment expertise support for incident and deviation/atypical investigations and applying effective root cause analysis and troubleshooting techniques (e.g. KT method, error proofing, etc).

• Leads root cause analysis investigations and resolution of complex equipment-related atypical events.

• Ensures all preventive actions relating to equipment are effectively implemented within the agreed time frame to prevent recurrence.

Equipment Change Controls (ECC}

• Supports implementation of ECC by participating in impact assessments, and executing field equipment modifications, including management of project schedules, resource plans, vendor coordination, and material purchases.

• Completes pre- and post-execution approval of IQ documentation and ensures that documentation meets required regulatory standards.

• Leads field walk-downs.

• Participates in HAZOP reviews.

Continuous Improvements

• Leads development of a continuous improvement framework within the maintenance group and actively supports the overall lPT improvement program.

• Ensures the IPT Maintenance Leads/Engineers have the knowledge and utilize Lean Six Sigma Tools (such as DMAIC, Kaizen, SMED, and 5S) to support execution of continuous improvement and OE projects intended to increase agility, flow and throughput, and also to reduce cycle time and inventory.

Financial Stewardship

• Achieves Production, IPT cost effectiveness, and product cost reduction targets set in the Profit Plan, with particular emphasis on equipment reliability and maintenance expenses.

• Monitors the IPT maintenance program to ensure it is cost-effective, including: spare parts levels and frequency of scheduled PM and equipment breakdowns)

• Effectively manages and plans labor utilization, minimizes overtime usage, and promotes a culture of low absenteeism.

Quality / SHE Stewardship

Quality

• Supports IPT Process Engineers to ensure all deviations, atypicals and customer complaints are fully investigated with any equipment related actions effectively implemented within the agreed time frame to continually improve processes, prevent waste, and eliminate rework.

• Supports the IPT in improving "Right First Time" performance through deviation reduction and the provision of error proofed documentation.

• Ensures all direct reports receive required cGMP and role-related training required to work safely and in compliance with regulatory requirements as identified in the individual training plan.

• Manages SOPs to ensure compliance to regulatory standards and ensures PM related documents are generated and maintained to required standards and appropriate frequency.

• Ensures equipment related activity is completed according to established procedures and all associated documentation is completed to a high standard.

• Ensures all 'Out of Tolerance' equipment findings are appropriately documented and investigated.

• Ensures technical documentation is made available during regulatory inspections, provides technical expertise and implements corrective actions as documented following regulatory inspections and internal audits.

Safety, Health & Environment

• Works with Director, Operations to maintain and improve SHE performance within the IPT, including ensuring SHE Risk Management & Change Management systems are effective, work area risks communicated, and adequately controlled.

• Ensures all direct reports are trained in accordance with SHE policies and guidelines.

• Demonstrates and promotes SHE leadership behaviors to all direct reports and engages employees at all levels on SHE issues.

• Ensures required risk assessments, including HAZOPS, are carried out for the IPT in a timely manner, recommendations provided, and implemented as agreed.

• Ensures permit requirements are met for all maintenance activities within the IPT.

• Participates in and supports implementation of actions for all Incident Investigations and Audits

People Excellence

People Management

• Works with Director, Operations and Maintenance Leads to implement Performance Management Process (PMP) effectively, ensuring objectives are developed, timely continuous feedback is provided to direct reports, and Maintenance team members are appropriately rewarded based on performance and demonstration of our leadership standards.

• Promotes a culture of continuous learning and identifies opportunities to multi-skill Engineers and Technicians.

• Ensures all direct reports have a development plan which supports achievement of objectives and future professional growth. Responsible for developing Employee Development for all direct reports, with the employee, and effectively mentoring to enhance performance.

• Delegates decision making to most appropriate level.

• Maintains positive working relationships among employees and fosters an environment where employee engagement, empowerment, teamwork and accountability are the cultural norm.

• Provides effective, regular and timely communication to their team and ensures that continuous feedback is given to support team performance.

Self

• Demonstrates leadership behaviours in alignment with our leadership standards.

• Develops and updates performance objectives and accomplishments in myPMP system and hold discussion on Employee Development Plan (EDP) with Manager aligned with Performance Management Process.

• Ensures both operational knowledge and technical skills are maintained and compliant against individual training requirements.

• Participates in SHE, Business Compliance, cGMP and all other compliance-related matters, where applicable

• Supervises and oversees Third Party Contractors, where applicable

• Any other duties as and when assigned by the Manager.

Qualification:

• Bachelor's Degree in Mechanical or Electrical Engineering

Experience:

• At least 8 - 10 years of relevant technical experience in Pharmaceutical or manufacturing industry including:

• Process equipment support

• Strategic maintenance and equipment reliability planning Project Management

Prefer experience with continuous improvement, Lean Six Sigma methodology, and application of Lean tools.

• People supervision experience

• Well-versed in applicable regulations and divisional policies/guidelines, especially Equipment Design, Equipment Qualification, Preventive Maintenance, and Calibration

• Demonstrated knowledge of process equipment and maintenance for appropriate areas

• Good stewardship awareness, including: cGMP, regulatory inspection preparation, and SHE

• Demonstrated knowledge and application of Lean Six Sigma methodology and tools

• Good understanding of maintenance programs, including: preventative maintenance, predictive maintenance, and reliability-centred maintenance

• Demonstrated capability in application of appropriate trouble-shooting and problem solving techniques

Other Personal Attributes:

• Demonstrate our Inclusive Behaviors

• Effective communication skills

• Ability to coach, motivate and lead others through change

• Demonstrated business acumen including:

  • performance planning: objectives setting, metrics, capacity planning, spares management.

  • financial stewardship: budget planning and oversight, maintenance expense and spares management understand the entire value stream and is customer focused.

Who we are

We are known as Merck & Co., Inc., Rahway, New Jersey, USA in the United States and Canada and MSD everywhere else. For more than a century, we have been inventing for life, bringing forward medicines and vaccines for many of the world's most challenging diseases. Today, our company continues to be at the forefront of research to deliver innovative health solutions and advance the prevention and treatment of diseases that threaten people and animals around the world.

What we look for

Imagine getting up in the morning for a job as important as helping to save and improve lives around the world. Here, you have that opportunity. You can put your empathy, creativity, digital mastery, or scientific genius to work in collaboration with a diverse group of colleagues who pursue and bring hope to countless people who are battling some of the most challenging diseases of our time. Our team is constantly evolving, so if you are among the intellectually curious, join us—and start making your impact today.

Current Employees apply HERE

Current Contingent Workers apply HERE

Search Firm Representatives Please Read Carefully 
Merck & Co., Inc., Rahway, NJ, USA, also known as Merck Sharp & Dohme LLC, Rahway, NJ, USA, does not accept unsolicited assistance from search firms for employment opportunities. All CVs / resumes submitted by search firms to any employee at our company without a valid written search agreement in place for this position will be deemed the sole property of our company.  No fee will be paid in the event a candidate is hired by our company as a result of an agency referral where no pre-existing agreement is in place. Where agency agreements are in place, introductions are position specific. Please, no phone calls or emails. 

Employee Status:

Relocation:

VISA Sponsorship:

Travel Requirements:

Flexible Work Arrangements:

Shift:

Valid Driving License:

Hazardous Material(s):

Requisition ID:R288203