Zach Fletcher
Atwater,CA
Summary
Experienced maintenance and engineering leader with a proven track record in managing teams and improving operational efficiency within high-volume manufacturing environments. Directed maintenance operations for multiple sites, overseeing project management for wide range of initiatives, while enhancing and implementing preventive maintenance and CMMS program solutions. Achieved significant improvements in equipment reliability and safety culture through the development of standard operating procedures and training programs tailored to Electro-Mechanical Technicians. Demonstrated ability to manage substantial budgets, driving cost reductions and optimizing resource allocation to meet strategic business objectives.
Overview
19
19
years of professional experience
Work History
Senior Maintenance Manager
Teasdale Foods
Atwater, Ca
03.2024 - 08.2026
- Managed & directed the maintenance team consisting of 2 Supervisors, 1 Maintenance Planner, and 18 technicians to meet site goals, and objectives for a Latin foods cannery site producing appx 45-55M lbs of beans and corn products.
- Improved the reliability, safety, and efficiency of all plant equipment and systems while driving continuous improvement initiatives. Site OEE improvement from sub-60% to mid-80% by 2026.
- Managed and developed AOP for the sites' maintenance and engineering needs that included capital, MRO, supplies, and labor.
- Managed projects from $5k to $5M, overseeing major equipment and line rebuilds, upgrades to control and mechanical systems, and facility infrastructure improvements.
- Redeployment of previous failed attempts to initiate a CMMS program. Improvements to the PM program, updating tasks and procedures to be more accurate and defining. Development of equipment BOMs to aid with better inventory management, part availability, and part lookup/access.
- Developed a strong safety culture that was lacking. Revamped the LOTO, confined space, hot work, and electrical safety programs to ensure compliance.
- Developed a training program in partnership with a local third party and internal teams for the new EMT roles.
Engineering & Maintenance Manager
Blue Diamond
Salida & Oakdale, Ca
02.2023 - 03.2024
- Directed the maintenance and engineering team for the Salida and Oakdale sites, overseeing 2 team leads, 1 project engineer, 1 reliability engineer, 1 maintenance planner, 1 coordinator, 3 controls technicians, and 32-35 technicians to maintain a 24/7 manufacturing operation.
- Managed R&M and labor budgets in excess of $10M. Developed a bottoms up AOP budget with intent to improve accuracy and accountability. Reduction in outside service spend of 8% in FY23 and on track for an approx 18% reduction for FY24.
- Promoted a continuous improvement culture by leading and developing RCA/RPS/FMEA into the culture of the maintenance & operations team. Significant win was the finding of a line not being run to recipe due to no standards in place, once utilizing OEM recipe the line went from appx 18% DT to less than 7% (below target/goal).
- Developed internal training program with other sites to enhance skills and advancement pathways for maintenance team; created SOPs and WIs to establish standard work.
- Transitioned maintenance team structure from mechanics and electricians to all Electro-Mechanical Technicians (EMT) in partnership with local technical college and state/county apprenticeship program.
- Managed R&M and labor budgets in excess of $10M. Developed a bottoms up AOP budget with intent to improve accuracy and accountability. Reduction in outside service spend of 8% in FY23 and on track for an approx 18% reduction for FY24.
- Transitioned the maintenance team from a mechanic & electrician structure to an all Electro-Mechanical Technicians (EMT). This was in partnership with a local technical college and state/county apprenticeship program.
Maintenance Manager
Land O'Lakes
Turlock, Ca
09.2020 - 02.2023
- Direct and supervise the maintenance team (1 PSM/Utilities Supervisor, 12 Technicians, 1 Purchasing/Receiving Clerk, 1 Maintenance Planner) for a dairy manufacturing site producing 2.5-4M lbs monthly. Also managed the preventative maintenance and repairs of all equipment (processing & packaging), facility, refrigeration, waste water, utility, and forklift/PIT.
- Introduced RCA and the 5 Whys methodology to the maintenance team for equipment failures, downtime, and troubleshooting practices, striving to instill a continuous improvement culture. This became part of pilot program in working with the corporate Asset & Reliability Team.
- Initiated and managed all capital projects for the site, ranging from $20k-1.8M encompassing production/equipment improvements and automation, safety, environmental, regulatory, refrigeration, etc. Notable projects were a robotic palletizer, robotic packer, new ammonia screw compressor replacement, and various controls upgrades due to obsolesce of existing systems.
- Initiated and managed all capital projects for the site, ranging from $20k-1.8M encompassing production/equipment improvements and automation, safety, environmental, regulatory, refrigeration, etc.. Notable projects were a robotic palletizer, robotic packer, new ammonia screw compressor replacement, and various controls upgrades due to obsolescence of existing systems.
- Managed vendor relationships to ensure accountability for service contracts and performance of services.
- Created business case for addition of Maintenance Planner role, securing approval for a salaried position to enhance maintenance operations.
- Ensure the maintenance team was properly trained in all aspects of their jobs to include safety, quality, and productivity.
- Interfaced with vendors and contractors as necessary to discuss products and services used in repair work and/or projects. Held vendors accountable for service contracts and actual services rendered.
- Ensured all regulatory compliance with various governmental agencies such as city, county, and state was met (RMP, CalARP, CUPA, PSM, OSHA, CARB/Valley Air, SQF, etc.)
Maintenance Manager
Mauser Packaging
Merced, Ca
04.2019 - 09.2020
- Direct and supervise the maintenance team (8 technicians) for machine, facility, and forklift preventive maintenance, breakdown repairs, and internal or capital projects to maintain OEE and KPI goals.
- Established an effective PM program that reduced downtime by 75-80% (no PM program existed, run to failure approach).
- Initiated and completed multiple capital projects ranging from automation of equipment, EHS improvements, increased production, etc. to $10k to $800k with a 1-2 year ROI.
- Introduced RCA and 5 Whys methodology to the maintenance team for equipment failures, downtime, and troubleshooting practices, striving to instill a continuous improvement culture. Implemented a daily activity log for each technician that was utilized to identify follow-up work, repetitive issues, or machine adjustments, and accountability for work performed.
- Restructured maintenance shop and spare parts area, enhancing maintenance department efficiency and response to equipment issues.
- Reduced maintenance overtime by implementing an optimized schedule for improved production coverage and increased opportunities for preventative and predictive maintenance tasks.
- Collaborated with vendors and contractors to evaluate products and services for repair work and projects.
- Provided PLC/controls support for all equipment at the plant; Omron & Allen Bradley
- Ensured all regulatory compliance with various governmental agencies such as city, county, state was met.
Maintenance Manager - MHE
JLL / Amazon
Stockton, Ca
04.2018 - 04.2019
- Directed and supervised the maintenance team (4 supervisors, 35 technicians, 1 MRO clerk, 1 PM Scheduler).
- Oversaw the performance of a team of technicians, supervisors, planners, and CMMS personnel across multiple shifts, executing proactive, preventative, and reactive maintenance on client equipment and facilities systems.
- Established and maintained safety-first culture through promotion of safe work practices and timely training.
- Led team and equipment performance initiatives aligned with client's Key Performance Indicators (KPI).
- Developed and managed operating expense budgets including monthly variance reports
- Managed subcontractors and suppliers to ensure delivery of goods and services per contract requirements.
- Contributed to Gemba activities aimed at enhancing workplace efficiency and safety., Utilized 5S techniques to improve workplace organization and efficiency., Facilitated root cause analysis sessions to determine factors contributing to equipment failures., Employed 5 Whys method to systematically investigate issues and enhance problem-solving efforts.
- Successful launch of new cross dock facility.
Maintenance Supervisor - PM / MRO
Foster Farms Poultry
Livingston & Fresno, Ca
09.2014 - 04.2018
- Directing and supervising the PM crew (18 technicians and 1 supervisor) and MRO staff (5 clerks and 1 supervisor).
- Implement, maintain, and schedule preventative and predictive maintenance tasks through the SAP CMMS system by analyzing historical records/data, evaluating equipment, and investigating the cause of the poor performance or failure of the equipment.
- Initiate major and minor rebuilds for production equipment with the goal of improving the effectiveness of the machine while reducing the cost.
- Introduced a cost savings partnership with a vendor in reviewing electric motor failures at the Fresno, Livingston, and Porterville facilities. All failed motors were sent to an EASA certified shop to be evaluated in which a report is generated for our review. Partnership included efforts to reduce investment cost (34-50% reduction), increase warranty utilization (previously 0.23% utilized), standardization (SKU reduction of 30-52%), and application assessments (increase efficiency and up-time).
- Developed a tool using Excel, MARS, and SAP to track equipment performance, monitor maintenance costs, labor, production throughput, and downtime to improve reliability.
- Improved overall inventory accuracy by 250% with improved processes and control, increased turn ratios, and reduced overall value on hand from $4.2M to $1.9M.
- Reduced cost by reviewing and analyzing the current sourcing of parts and materials and continuing to develop a more competitive environment between OEM and non-OEM vendors. Efforts to reduce operating cost by standardizing the MRO inventory and the potential to better leverage our purchasing contracts.
- Assisted with plant and capital projects; initiated and managed the MRO Security capital project, establishing it as corporate standard.
- Oversaw compliance with environmental regulations, ensured all regulatory compliance with various governmental agencies such as city, county, state was met.
Application Engineer
JBT FoodTech FPSD
Madera, Ca
07.2012 - 09.2014
- Project Manager for new machine and aftermarket upgrade projects from $50k to an excess of $15M and ranging from 3 months to 1+ years.
- Project Manager for new machine and aftermarket upgrade projects from $50k to an excess of $15M and ranging from 3 months to 1+years.
- Developed comprehensive proposals and quotes for equipment, parts, and rebuilds.
- Coordinated project and production schedules across all internal and external departments.
- Coordinated installation of equipment with customers and internal teams, managing multiple onsite installations of new and replacement systems to ensure project success.
- Responsible for standardizing the Static, Agitating, and Pilot Retort product lines to meet sales and engineering design initiatives and goals (reducing lead-time, reducing manufacturing cost, and standardization).
- Effectively communicated with customers throughout all phases of a project and continued to grow the working relationship.
- Developed estimating and capacity calculation tools and templates for engineering and sales departments, streamlining proposal processes.
Maintenance Coordinator
Foster Farms Poultry
Fresno, Ca
05.2011 - 07.2012
Inventory Manager / Shop Supervisor
Superior Distribution Center
Turlock & Fresno, Ca
07.2007 - 05.2011
Education
Associate of Science - Animal Science & Agricultural Science
Modesto Junior College
Modesto, CABachelor of Science - Industrial Technology
California State University, Fresno
Master of Science - Industrial Technology
California State University, Fresno
Skills
- Project management ranging from smaller to larger multi-million dollar improvements and new equipment/ infrastructure
- AOP and Capital budgeting development, forecasting, variance analysis and tracking to meeting strategic goals
- CMMS development, implementation, & administration to to improve the maintenance teams effectiveness
- Preventive maintenance program strategies, refinement, and accountability
- Reliability engineering utilizing fundamental tools such as RCA/5 Whys, FMEA, and data analytics
- Mechanical (hydraulics, pneumatics, welding & fabrication), Electrical (High and low voltage, AC/DC, motor control, and schematic/PID), and PLC knowledge and troubleshooting ability
- Team development through coaching and training, including individual contributors and leaders
Timeline
Senior Maintenance Manager
Teasdale Foods
03.2024 - 08.2026
Engineering & Maintenance Manager
Blue Diamond
02.2023 - 03.2024
Maintenance Manager
Land O'Lakes
09.2020 - 02.2023
Maintenance Manager
Mauser Packaging
04.2019 - 09.2020
Maintenance Manager - MHE
JLL / Amazon
04.2018 - 04.2019
Maintenance Supervisor - PM / MRO
Foster Farms Poultry
09.2014 - 04.2018
Application Engineer
JBT FoodTech FPSD
07.2012 - 09.2014
Maintenance Coordinator
Foster Farms Poultry
05.2011 - 07.2012
Inventory Manager / Shop Supervisor
Superior Distribution Center
07.2007 - 05.2011
Associate of Science - Animal Science & Agricultural Science
Modesto Junior College
Bachelor of Science - Industrial Technology
California State University, Fresno
Master of Science - Industrial Technology
California State University, Fresno