Position Maintenance Manager
Location: Ashtabula, Ohio (USA)
Recruiting Manager: Derek Lebzelter, VP of Operations & SHE
Desired start date: March 2024

ABOUT INEOS KOH

INEOS KOH, Inc. – The KOH production facility is in Ashtabula, Ohio. It safely and efficiently produces potassium hydroxide (KOH) and chlorine (Cl₂) by the membrane process. KCl salt is electrolytically converted to KOH and Cl₂ by the application of electricity in INEOS membrane electrolyzers. The site employs about 100 people.

ORGANIZATION, CONTEXT and MAIN JOB PURPOSE

The role provides overall leadership for the safe, reliable, legally compliant, environmentally sound and profitable maintenance of equipment for manufacture of products at this plant according to the strategy of business management. This includes managing and developing internal maintenance resources and managing external maintenance resources. Driving continuous improvement in support of existing KPIs and future growth is a critical part of this role.

KEY RESPONSIBILITIES AND ACCOUNTABILITIES

The Maintenance Manager of INEOS KOH manages 5 direct reports and leads an organization of 22 people in total. The jobholder works closely with their peers in Operations, Engineering/Quality and SHE to improve on SHE, plant reliability and asset care.

The jobholder is part of the leadership team and is expected to act as a leader of the organization by role modelling important behaviours such as safety, ownership, creativity, and manners.

The jobholder ensures all individuals in their organization have the necessary skills to perform their jobs, identifies key performance objectives and motivates the team to deliver on or exceed above expectations, defines succession planning to keep a fully staffed organization, develop and mentor high potential individuals and work with team members to overcome performance issues.

Key figures:

Maintenance spend	$6m
ERV*	$250m
Direct reports	5
Indirect reports	17

*Equipment Replacement Value

Specifically, the jobholder focuses on the following functional accountabilities:

Drive SHE Excellence:
- Champion for the 20 principles of process and behavioral safety and life-saving rules
- Perform as the INEOS KOH Maintenance Manager
  - Have employees and maintenance systems prepared to respond to site emergencies.
  - Ensure assets are maintained to operate within their designed parameters.
  - Ensure robust safe work systems are in place and hazard assessments performed (both process & behavioral).
- Drive site maintenance team to SHE (including process safety) targets and demonstrate improvements for employees and contractors

Performance indicators: TRIR, Number of process safety incidents (LOC10, overdue inspections), AsCare score

Reliability:
- Develop systems to ensure reliability continually improves by improving overall equipment performance.
- Develop KPI to demonstrate continuous improvement in reliability.
- Ensure data is utilized in development of reliability improvement plans.
- Manage critical spare equipment processes and inventory to best support overall reliability while minimizing cost and working capital.
- Manage planned annual maintenance outage.
- Safely manage unplanned outages to minimize downtime and return systems to production.

Performance indicators: % plant reliability, PM performance attainment, % Reactive work, Schedule Compliance, Annual outage on time and in budget

Maintenance: define and implement asset maintenance programs and procedures to maintain or improve asset performance and condition (asset care) and develop plans to improve equipment reliability.
- Set up and manage preventative and predictive maintenance routines and update work processes to ensure site is efficiently maintained.
- Ensure team works with the reliability engineer and operations team to understand the root cause of breakdown issues, to support development of equipment specific policies, and to support design or process changes to improve reliability.
- Carry out annual review of asset condition and use as the basis for maintaining an asset life plan.

Performance indicators: Mean time between breakdowns, Backlog of mechanical and I&E work orders, Live temporary repairs

Budget: prepare, agree, and ensure delivery of annual maintenance fixed cost budget. Lead the analysis of maintenance spend and the identification and implementation of cost improvement initiatives.
- Ensure compliance with work management systems which allow control of work and spend.
- Coach team to deliver cost effective solutions.
- Develop and maintain KPIs to monitor performance to budget.
- Lead regular expenditure reviews with team and provide support to fixed cost reduction.
- Act as primary contact for purchasing, proactively support procurement excellence initiatives.

Performance indicators: maintenance supply expenses (NMPFC), labor cost (overtime with clear approval process), comparison of budgeted and actual project costs, timeline & deliverables

Leadership: develop and maintain a high performing organization
- Lead the use of maintenance best practices.
- Develop and maintain KPIs to monitor team performance.
- Actively manage the competence and training needs of the team.
- Provide leadership, guidance, coaching and decision making, to ensure employees understand company goals, policies and processes, and have the knowledge and resources needed to accomplish them.
- Maintain an engaged and motivated workforce. Report opportunities and risk to management.
- Lead by example; model senses of urgency, ownership, and discipline.

Performance indicators: absenteeism, overtime, unfilled positions, training, qualification of staff for next levels, feedback from peers and subordinates

Who	Frequency	My role	Purpose of contacts
COO	Monthly	Report & Seek support/escalation	Report during monthly leadership meetings, engage as needed on sensitive matters
Vice President of Operations and SHE	Frequent	Report & Seek guidance	Provide timely updates and keep VP informed of specific issues which may occur and/or require leadership guidance
Maintenance Supervisors & Leads	Daily/Weekly	Manage & inform	Provide support and guidance, understand plant issues. Receive information, provide feedback Maintain plant operations, training guidance. SHE and business communications, plant operations
SHE Manager	Ad hoc	Collaborate and support	Resolution of SHE issues
Operations Manager	Frequent	Collaborate and support	Prioritization of maintenance work & alignment on work priorities.
Engineering Manager	Ad hoc	Collaborate and support	Work on mechanical integrity, plant reliability and other plant improvements.

SKILL and EDUCATION

Level of education and Experience in general

Bachelor’s degree in science or engineering preferred
Possess a minimum of ten (10) years of related experience in a manufacturing environment
Highly developed knowledge of operations or maintenance
Leadership/management skills
Knowledge of various electrical equipment, instruments and pneumatic devices
Knowledge of various equipment and machinery
Mechanical Aptitude – use of precision measurement tools and assembly techniques
Understanding of Chemistry and Physics
Working knowledge of chemical/industrial equipment function, design, and regulatory requirements and PSM Mechanical Integrity
Understanding of Welding Principles
Equipment Vibration and Alignment Experience
API 510, 570 and 653 Experience
ISO System and procedures knowledge
Functionality with various computer programs, specifically Microsoft Office Suite and SAP

HOW TO APPLY

Please send a CV and covering letter to Steve Kane steve.kane@ineos.com and Derek Lebzelter derek.lebzelter@ineos.com by 2/23/2024.