Senior Maintenance Manager – Automated Distribution Center

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Senior Maintenance Manager - Automated Distribution Center

Position Summary

Lead all maintenance operations for a highly automated distribution facility featuring advanced material handling systems including ASRS, conveyor networks, and robotic equipment. Direct a multi-shift maintenance team of 22 professionals ensuring 24/7 operational excellence across complex automated systems.

Key Responsibilities

Leadership & Operations 

• Manage maintenance team including 1 Coordinator, 3 Senior Technicians, and 18 Technicians across three shifts.
• Develop workforce planning, training programs, and performance management strategies.
• Foster a culture of safety, continuous improvement, and technical excellence while ensuring 24/7 operational coverage.

Equipment & Systems Management 

• Oversee preventive and corrective maintenance programs for automated systems including 10 Viastore Viapal unit load cranes (44,800 storage locations), 20 TGW Mustang miniload cranes (168,825 tote locations), 14,000+ linear feet of conveyor systems, sortation equipment, 9 autonomous vehicles, 7 Fanuc robotic arms, and specialized material handling equipment.

Strategic Planning 

• Develop and execute comprehensive preventive maintenance schedules. Establish and monitor KPIs for equipment uptime, MTBF, and MTTR.
• Manage spare parts inventory, vendor relationships, and annual maintenance budget.
• Implement predictive maintenance strategies leveraging equipment diagnostics.

Compliance & Safety 

• Ensure all maintenance activities comply with OSHA, ANSI, and manufacturer standards.
• Conduct regular safety audits and risk assessments.
• Maintain complete equipment documentation including manuals, schematics, and maintenance histories.

Required Skills

• Bachelor's degree in engineering, Industrial Maintenance, or related field (or equivalent experience)
• 10+ years progressive maintenance experience in automated distribution or manufacturing environments
• 5+ years leadership experience managing multi-disciplinary maintenance teams
• Extensive knowledge of ASRS systems (Viastore, TGW, or similar platforms)
• Strong understanding of conveyor systems, sortation technology, and material handling equipment
• Proficiency in PLC programming and troubleshooting (Siemens, Allen-Bradley, or equivalent)
• Working knowledge of electrical systems, mechanical systems, and industrial controls
• Proven ability to lead and develop high-performing technical teams
• Strong problem-solving and decision-making skills under pressure
• Excellent communication skills across all organizational levels
• Budget development and cost control experience
• CMMS software proficiency (SAP PM, Maximo, or similar)

Preferred Skills

• Experience with automated guided vehicles (AGV) or autonomous mobile robots (AMR)
• Demonstrated project management capabilities with complex automation projects
• Lean Six Sigma certification (Green Belt or higher)
• Experience with Viastore and TGW systems specifically
• Advanced PLC programming capabilities
• Predictive maintenance and reliability engineering background
• Multi-site maintenance management experience

Physical Requirements

Ability to work in distribution center environment with varying temperatures. Capability to access all areas of automated systems including elevated platforms and confined spaces. Flexibility to respond to emergency maintenance situa