Maintenance Manager

Company:

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Job title: Maintenance Manager

Job Location: Chocolate Bayou Works in Alvin, TX

Salary Range: $179,138.00 - $223,923 commensurate with experience

Organizational Context and Job Purpose

The Olefins & Polymers USA division of INEOS is one of the largest producers of olefins and polyolefins in North America. From its manufacturing locations at Chocolate Bayou and the Battleground Manufacturing Complex, it is a merchant marketer of butadiene, ethylene, polypropylene and high-density polyethylene with annual revenue of over $4B. The Chocolate Bayou Site is located in Southeastern Texas about 40 miles South of Houston and consists of two Olefins units that produce approximately 4bn pounds/year of ethylene, 2 Polypropylene units that produce approximately 1B pounds/ year of polypropylene, and the Light Ends storage & transfer facilities at Stratton Ridge.

The Maintenance Manager is responsible for all aspects of Routine and Unusual maintenance activities for the various areas of the facility.  The role is responsible for planning, execution, and delivery of services which averages over $100M per year of expense and capital per year that supports the site asset base.  This position is responsible for ensuring that all maintenance and reliability PMs are executed in a timely, safe, and efficient manner and that equipment is maintained to ensure mechanical integrity and reliability. This role reports to the Site Director and has responsibility for both embedded contractors and INEOS employees.

Responsibilities and Accountabilities

• The position is accountable for understanding and putting into practice the INEOS 20 Principles.  Additionally, the Maintenance Manager has a special responsibility to cascade the understanding of these principles through their team.
• Ensure HSE delivery and compliance for Maintenance activities in the unit areas; serving as a champion for safe work practices for both INEOS employees and contractors working within the areas.  Accountable for safety of the work team inclusive of training, incident prevention behaviors, near miss reporting/root cause analysis and shared learnings, and championing the MOC and related PSM processes.
• Devise and manage a discipline strategy consistent with the long and short term asset and business strategies.
• Ensures external and internal compliance for safety and environmental preventative maintenance requirements and inspections.
• Responsible for the safe and efficient planning and execution of routine maintenance services, as well as the execution and the management of the onsite maintenance contractors. Additional responsibilities include implementing or coordinating equipment inspection, integrity services, and materials management. 
• Jointly responsible for improvement of overall equipment and process reliability; this includes budgeting for and supporting areas such as inspections, vessel CUI re-conditioning, Area Reliability Team improvement projects for assets, and focus on defect elimination.
• Ensure the effective planning and execution of project-related activities; serving as single point of accountability (SPA) for various capital maintenance projects (such as furnace retubes and maintenance upgrades).
• Develop and maintain strategic long-term plan for maintaining site assets.  Interacts with industry experts to seek out and apply new technology and best practices to improve maintenance planning, tracking, and execution. 
• Act as the SPA for developing and maintaining close relationships with vendors and contractors for materials and maintenance services.  Liaison with Procurement to negotiate pricing and timing. 
• Develop needed resource skill sets to support site teams’ efforts for maintaining the assets (hiring, training, development, discipline know how).  Responsible for leading and developing competency development programs for Millwright, Instrumentation, Electrical Distribution, and Analyzers.
• Ensure Mechanical, Electrical, and Instrumentation Training program is current, that proper training funds are budgeted annually, and that the required training is completed.
• Ensure the acquisition and sharing of best practices across the company. Develop company and external industry contacts to network issues on codes, standards and practices. Facilitating network and relationship development, including Europe, to enable technology to optimize maintenance practices.
• Responsible for development and cost reporting for several Maintenance cost centers for both routine and unusual maintenance budgets.  This includes providing monthly updates during the Group Financial Outlook (GFO) financial process.

Maintenance Planning and Delivery Management

Responsible for developing the overall Maintenance strategy for all assets at the site.

• Ensure that reusable job plans are created and scheduled in accord with recommendations from the engineering teams.
• Develop and maintain the RIME ranking process for prioritization of maintenance work.
• Solicit feedback on executed jobs plans and make any necessary changes to ensure that planning and work efficiency continues to improve.
• Develop and publish maintenance and planning metrics for the site.
• Prioritize, with operations customer base, the overall maintenance improvement plan and implement new/different approaches to deliver cost reductions, increased reliability and operational flexibility.
• Prioritize and represent capital request for the site equipment and spare parts that are consistent with the long-term sustainability of the asset and the business strategy.

Accountability 1: Safety performance in area of responsibility

• Ensures adherence to policy, procedures and practices
• Ensures compliance to INEOS Group Guidance Notes (IGGN) standards and 20 Principles
• Attendance at daily, weekly and monthly safety meetings
• Ensures utilization of HRP (Hazard Recognition Plus), job observation cards, Job Safety Analysis (JSA), Behavioral Safety Program (BSP), and incident tracking system (Gensuite)
• Develop/implement strategy for asset maintenance that supports SHE goals

Accountability 2: Compliance with internal and external policies and regulations

• Timely completion of HAZOP, incident investigation, PSM, and other recommendations
• Ensure inspection records, Relief Valves (RV’s), Safety Critical PMs, and legally required PM’s are current on all equipment and piping circuits.

Accountability 3: Ensure mechanical integrity of assets

• Adherence to API, ASME and ANSI standards and industry practices
• Working knowledge of industry standards and emerging trends
• Audit compliance with PSIM standard and take corrective action as necessary

Accountability 4: Ensure availability of asset

• Effective maintenance planning and efficient execution of routine work
• Effective capital planning and execution
• Leverages technology and procedural efficiencies to implement best practices and reduce lifecycle cost
• Develop and keep evergreen the long term asset maintenance strategy, including revamps and new technology upgrades
• Support the teams in implementation of small reliability projects for improved production and reduced fixed and variable costs.

Accountability 5: Assist Asset Managers to forecast and manage Maintenance budget

• Support development of annual maintenance budgets
• Forecast spending pattern for the year.  Review actual maintenance costs vs. planned costs and provide monthly variance analysis
• Actively manage vendor relationships to optimize delivery, pricing, and work performance of suppliers and contractors. Act as the SPA for developing and maintaining close relationships with suppliers and contractor vendors.

Accountability 6: Forecast and manage annual budget for large maintenance events and outages

• Develop annual outage budget
• Forecast spending pattern for the year.  Make proactive adjustments to contract work force to manage backlog.
• Actively manage vendor relationships to optimize delivery, pricing, and work performance of suppliers and contractors. Act as the SPA for developing and maintaining close relationships with material and contractor vendor providers.

Accountability 7: Strategic Planning for Site and Asset Optimization

• Key participant in strategic planning for long term asset strategy and optimization
• In addition to monthly KPIs, ensure robust asset multi-year analysis to assess success/robustness of maintenance program and assets.
• Drive negotiations with strategic vendors
• Develop strategic planning/vision for Maintenance roadmap.   Develop monthly metrics to track progress to the plan.

Skills and Knowledge Required

Educational Background and Work Experience

• Undergraduate degree in Engineering or equivalent experience leading a maintenance organization is required. 
•  A minimum of 10 years’ experience in chemical, refining or industrial manufacturing with prior responsibility for facilitating critical functions and best practice implementation. 
• A minimum of 3 years of direct leadership experience in a maintenance organization.

Skills and Competencies

Technical skills

• Deep knowledge and experience in Integrity codes including API570, API571, API580, API581, and API653
• Deep knowledge and experience in Maintenance best practices
• Experience and knowledge of chemical operations and maintenance
• Experience and knowledge of OSHA 1910.119
• Experience and knowledge of TAR/Capital planning and execution
• Experience in multi disciplines (I/E, Mechanical Fixed, Rotating, Analyzer)
• Strong financial acumen
• Familiarity with process and personnel safety systems
• Deep expertise required in engineering practices and codes
• Has the insight based on knowledge and experience to identify undefined restrictions in processes and systems and create solutions
• Interacts with industry experts to apply new technology as intended to existing practices to achieve improved business performance

Behavioral skills

• Integrity and trust
• Strong work ethic
• Results driven
• Strong decision-making skills
• Ability to prioritize and organize work
• Able to relate to multiple levels in the organization
• Able to delegate and hold people accountable
• Ability to establish and grow cross-functional team to accelerate improved performance
• Strong communication skills
• Ability to communicate effectively at all levels of the organization. 
• Effectively balance competing priorities and provide direction and leadership for their teams.
• Ability to resolve conflict
• Willingness to challenge the status quo.
• Considers a broad range of internal and external factors when solving problems.
• Can see applications and practices from different processes and industries that could benefit our business.

Line Management Responsibility

This Maintenance Manager has approximately eight (8) direct reports and one hundred thirty seven (137) indirect employees.  The position provides direct INEOS oversite for approximately 315 embedded contractors along with the bidding, planning, job rep support, and management of additional contractors on an annual basis for asset outages and maintenance projects (specialty welding, industrial cleaning, NDE, refractory, Scaffold/Insulation/Paint, Civil, Treater Media change-outs, etc.)

Our culture is one of honesty and integrity with an emphasis on safety, health and environmental performance.On our team, people are acknowledged for embracing new practices that help create real value for customers.