Facility 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 Summary

Qual 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:

1. Facility Maintenance & Infrastructure


2. 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 Responsibilities

1. Maintenance Leadership & Team Development

• Lead, 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

2. Equipment Reliability & Automation Support

Oversee 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

3. Facility & Infrastructure Management

Although 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

4. Safety & Compliance Leadership

• Champion 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.

5. WMS / PMMS System Ownership

• Ensure 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.

6. 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 Qualifications

• 5+ 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 Qualifications

• Experience 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 Competencies

The 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 Accountability

• Own maintenance-driven downtime performance.


• Partner with Operations to drive OEE improvements.


• Identify systemic reliability risks and implement long-term corrective strategies.