Maintenance Reliability Consultant Jobs in Indiana

Job Title: MAINTENANCE PLANNER 
Location: Warsaw - IN 
Level: Senior 
Client Facing: Yes  

About PAC Group: 

At The PAC Group (PAC), we specialize in engineering consulting, program management, and operational excellence-delivering high-impact solutions in more than 20 countries. We're proud to partner with the world's leading companies in automotive, aerospace, industrial, and technology sectors, providing strategic guidance and hands-on execution that drive innovation and efficiency. Whether we're launching advanced manufacturing systems, deploying digital simulation tools, or scaling global operations, PAC thrives at the intersection of technology, engineering, and problem-solving. 

Joining PAC means joining a dynamic, fast-paced, and global team that values curiosity, collaboration, and continuous improvement. 

Role Purpose: 

The Maintenance Planner will be responsible for planning and implementing a plant maintenance system covering the daily operations, maintenance, and improvement of the manufacturing facility with a strategic data-driven approach. This role supports equipment reliability needs and is one contributor to maintain a safe and efficient work environment. 

Key Responsibilities: 

Implementation of Maintenance System and Strategies: Implementation of a Computerized Maintenance Management System (Maximo). This includes creating a detailed, digitized inventory of all facility equipment (conveyors, paint booths, HVAC, robotics) with unique IDs and critical ratings. Develop and implement a comprehensive Preventive Maintenance schedule (daily, weekly, monthly, annually) based on OEM recommendations, environmental conditions, and production demands. Integrate sensors (vibration, temperature, etc.) in monitoring facilities equipment conditions to identify early signs of failure to ensure continuous and efficient plant operations through Predictive Maintenance Strategy. Establish a critical spare parts warehouse strategy, setting min/max levels to minimize downtime during unexpected failures. Document maintenance routines, checklists, and troubleshooting guides to standardize operations. 

Daily Operations and Reliability: Diagnose root causes of equipment failures, leading corrective maintenance to restore production. Oversee the lifecycle of maintenance work-request, assignment, execution, and closure-ensuring all activities are logged in the CMMS. Oversee external vendors for specialized maintenance (electrical, plumbing, HVAC, fire systems) ensuring compliance with safety and quality standards. Analyze performance data to maximize equipment uptime, reliability, and speed. Manage departmental budgets, tracking maintenance costs and spare parts spenditures to optimize ROI. 

Continuous Improvement and Safety: Perform post-mortem analysis on failures to prevent recurrence. Track Key Performance Indicators (MTBF-Mean Time Between Failures, MTTR-Mean Time To Repair, PM Compliance) to evaluate and adjust the maintenance program. Ensure full compliance with safety standards (e.g., Lockout/Tagout, OSHA/local regulations) and environmental regulations (waste disposal, emissions). Identify and implement improvements to assembly line equipment using Lean tools to increase efficiency. Train maintenance technicians on new equipment and best practices. 

Required Qualifications: 

Education: A Bachelor's degree in Mechanical, Electrical, or Industrial Engineering. Equivalent technical experience with a relevant trade certification may be considered. 

Experience: Minimum of 5-7 years of experience in industrial maintenance planning, scheduling, or reliability engineering. 

Proven experience leading the successful implementation, configuration, or major asset-mapping overhaul of a CMMS/EAM system (specifically IBM Maximo). 

Deep expertise in developing asset hierarchies, establishing unique ID structures, and conducting criticality assessments for automotive/heavy manufacturing equipment (conveyors, bonding, HVAC, robotics). 

Strong hands-on experience designing Preventive Maintenance (PM) programs and deploying Predictive Maintenance (PdM) technologies (e.g., vibration analysis, thermal imaging, sensor integration). 

Demonstrated ability to establish Maintenance, Repair, and Operations spare parts warehouse strategies, including calculating min/max levels and economic order quantities. 

Experience managing civil site utilities, wastewater treatment plants, and facility infrastructure. 

Mastery of maintenance KPIs (MTBF, MTTR, PM Compliance) and Root Cause Analysis (RCA) methodologies. 

Thorough knowledge of OSHA regulations, Lockout/Tagout (LOTO) protocols, and environmental compliance (waste and emissions). 

Experience applying Lean Manufacturing principles, 5S, or Six Sigma tools to optimize assembly line efficiency. 

Preferred Qualifications: 

Certified Maintenance & Reliability Professional (CMRP) or Certified Maintenance & Reliability Technician (CMRT) designation. 

IBM Maximo Certified Deployment Professional or advanced Maximo super-user certification. 

Experience in high-volume, fast-paced manufacturing environments (e.g., automotive, aerospace, or advanced fulfillment centers) experiencing rapid scaling or product launches.