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Vulcan Elements manufactures American rare-earth permanent magnets for defense, aerospace, and automotive applications. This is a greenfield role establishing maintenance and reliability infrastructure from the ground up ahead of facility startup.
The Senior Manager designs and deploys the complete maintenance ecosystem, then leads the organization that operates it. This is a high-impact, foundational role with accountability across five major domains:
**Maintenance Program & Management System**: Design the work management process, roles, decision rights, and performance standards. Establish the full workflow from work notification through closeout (prioritization, planning, kitting, scheduling, execution, closeout). Define maintenance strategy by asset criticality. Build the performance framework (PM compliance, wrench time, backlog health, emergency work ratio, MTBF/MTTR, maintenance cost per unit). Own Mechanical Integrity for PSM-covered equipment in partnership with EHS.
**CMMS & ERP Configuration**: Lead platform selection and functional configuration (work order types, approval workflows, planning, scheduling, mobile execution). Design the asset hierarchy, equipment numbering, and master data governance. Build the PM library and failure taxonomy from OEM data and criticality analysis. Configure ERP stock masters, storeroom workflows, min/max levels, and work order cost capture. Link equipment BOMs to stock items. Own testing, training, go-live, and adoption.
**Reliability Engineering & Asset Strategy**: Establish criticality ranking across the asset base. Build the reliability program (FMEA, asset strategy reviews, root cause analysis, bad-actor management). Stand up predictive maintenance (vibration, thermography, oil analysis, ultrasound, motor testing) with routes, thresholds, analyst qualification, and escalation. Set precision maintenance standards (alignment, balancing, fastening, lubrication, cleanliness) and partner with Manufacturing Engineering on design for reliability.
**MRO, Stores & Spare Parts**: Stand up the central storeroom (layout, bin scheme, receiving, issue, security, cycle counting). Build spare parts strategy grounded in criticality, insurance spares for long-lead items, and vendor-managed inventory. Capture commissioning spares during installation. Manage MRO inventory value, turns, and stockout performance.
**Organization Design & Development**: Establish the central specialty trades pool (welding, rigging, precision alignment, lubrication, condition monitoring). Recruit, train, and develop the maintenance organization to startup schedule.
Primary deliverables: configured CMMS and ERP environment with validated master data; documented work management process; criticality-based preventive and predictive maintenance program; stocked and governed central storeroom; audit-ready Mechanical Integrity program; qualified maintenance organization ready for line startup.
**Requirements**
Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.
**Preferred Qualifications**
- Demonstrated ownership of a CMMS implementation (asset hierarchy design, PM library build, work management workflow configuration, go-live adoption)
- Greenfield or major expansion experience standing up maintenance in new facilities
- PSM-regulated site experience with direct Mechanical Integrity program ownership
- CMRP, CRL, or equivalent professional certification
- Background across relevant asset classes: vacuum furnaces, thermal systems, hydraulic presses, powder and material handling, CNC machine tools, plating, wastewater, utility plant equipment
- Lean, TPM, or Six Sigma certification with applied maintenance projects
- Master's degree or MBA
