Overhaul Project Manager

About LightForce LightForce is leading the digital transformation of orthodontics and redefining the standard of care for patients. Our fully digital, 3D-printed orthodontic platform increases practice efficiency, improves clinical consistency, and enables more predictable treatment outcomes. Unlike traditional stock brackets, LightForce delivers fully customized, patient-specific brackets paired with AI-driven treatment planning—optimizing outcomes at scale. With recent advancements unlocking the next phase of digital orthodontics, LightForce continues to push the boundaries of what’s possible in personalized care. Learn more at www.lf.co Description The Maintenance Manager at LightForce Orthodontics is accountable for the reliability, compliance, and continuous improvement of all maintenance operations across a 24/7 advanced manufacturing facility. This role leads the maintenance team with direct responsibility for hiring, development, performance management, and day-to-day supervision. The Maintenance Manager owns the preventive maintenance program, hazardous waste compliance program, and serves as the primary maintenance point of contact for production, engineering, and R&D teams. This position requires a leader who operates with a high degree of ownership, drives results through people and process, and upholds the documentation and compliance standards that underpin the facility's operational and regulatory posture.  Essential Duties & Responsibilities: * Directly supervise Maintenance Technicians I, II, and III across all shifts; manage scheduling, coverage, and on-call rotation to ensure 24/7 maintenance support * Conduct regular 1:1 meetings, provide ongoing coaching and performance feedback, and complete formal performance reviews during annual cycles * Hold team members accountable to documentation standards, work order completion quality, and CMMS compliance; address performance gaps through structured corrective action when necessary * Identify skill development needs across the team; coordinate on-the-job training, vendor-led instruction, and external certification opportunities * Triage and prioritize corrective maintenance requests based on production impact and urgency; coordinate resources to minimize equipment downtime * Oversee execution of the preventive maintenance program across all production equipment and facility systems including furnaces, compressed air infrastructure, and instrumentation * Perform and support complex troubleshooting of furnace systems, compressed air systems, electrical systems, and additive manufacturing production equipment * Coordinate daily maintenance rounds; identify, document, and drive resolution of emerging equipment and facility issues before they impact production * Own the hazardous waste compliance program: oversee container labeling, accumulation timelines, and inspection logs * Ensure all maintenance records are maintained in accordance with regulatory requirements; ensure CMMS documentation reflects accurate work history, asset data, and compliance status Develop, review, and update standard operating procedures and work instructions as process improvements or equipment changes are implemented * Lead root cause analysis for recurring equipment failures; drive corrective actions from initiation through verified closure and document findings in CMMS * Drive 5S and lean manufacturing practices across maintenance areas and production floor touchpoints * Manage contract service providers: enforce SOP compliance, hold vendors accountable to service level expectations, and escalate performance issues to the Operations Manager Participate in design reviews for new equipment and provide maintainability input during capital project planning  Education & Experience * 2+ years in a managerial or supervisory maintenance role with direct reports, including demonstrated experience in performance management and team development * Experience working in an industrial manufacturing setting is preferred * Completion of a state-accredited journeyman or technical school program, or equivalent formal training with demonstrated field proficiency is preferred *  5+ years of progressive industrial maintenance experience in a manufacturing or precision production environment * Prior experience in a 24/7 continuous-process manufacturing facility is a plus * Experience in an additive manufacturing, medical device, aerospace, or similarly regulated production environment is a plus  Technical Skills and Knowledge * Deep working knowledge of industrial furnace systems, thermocouples, and high-temperature electrical systems * Proficiency with compressed air systems including distribution, regulation, dryers, and major overhaul procedures * Advanced electrical competency including schematics, 3-phase systems, VFDs, PLCs, and panel-level troubleshooting up to 480V * Strong proficiency in CMMS platforms (MaintainX, Fiix, eMaint, or equivalent), including preventive maintenance creation, work order management, asset history tracking, and maintenance reporting * Ability to read and interpret electrical schematics, mechanical drawings, and P&IDs * Proficiency with Microsoft Office Suite and Google Suite  Preferred Qualifications * Licensed Electrician or equivalent formal electrical certification * Experience with additive manufacturing equipment including laser powder bed fusion or polymer-based 3D printing systems * Lean manufacturing, Six Sigma, or continuous improvement certification or formal training * PLC programming or advanced controls troubleshooting experience (Allen Bradley, Siemens, or equivalent) * Experience with capital project planning, equipment procurement, or factory acceptance testing Forklift, crane, or aerial lift operator certification  Physical Demands * Ability to stand, walk, and perform physical activity for extended periods in an active manufacturing environment * Ability to lift and carry up to 50 lbs unassisted * Ability to work in varied environmental conditions including heat, noise, and exposure to chemicals or airborne particulates * Ability to work with appropriate training, certification, and PPE * Valid driver's license with a satisfactory driving record require Perks * PTO/Paid Holidays * Medical, Dental, and Vision plans * 401k Retirement plan * Fringe benefits * Paid parental leave * Workplace perks such as food/coffee   To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed above are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.  It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liabilities. LightForce Orthodontics is an Equal Opportunity/Affirmative Action Employer and does not discriminate on the basis of race, color, religion, gender, age, national origin, disability, Protected Veteran status, sexual orientation, or any other characteristic protected by federal, state or local law.

YOUR MISSION Key Tasks * Propulsion System Leadership: Act as the technical authority for propulsion systems. Define system requirements, responsible for engine integration and verification methods. Collaborate with vendors to troubleshoot performance issues and drive design improvements. * Cross-Functional Integration: Work with aerodynamics, structural, and avionics teams to optimize engine integration, cooling, and vibration mitigation. Ensure propulsion systems align with the helicopter mission profiles (e.g., endurance, payload capacity, altitude, temperature, and other environmental factors). * Testing & Validation: Lead ground and flight testing campaigns to validate engine performance under operational conditions. Develop test campaigns and test plans. Analyze data to refine system parameters. * Vendor & Customer Management: Serve as the primary technical liaison between internal teams and propulsion system vendors. Review vendor designs, conduct risk assessments, and ensure deliverables meet project timelines. Support customer engagements to resolve requirements ambiguity. * Lifecycle Support: Develop maintenance protocols and failure-mode analyses for propulsion systems. Support field operations teams in diagnosing and resolving engine-related issues. Develop and maintain strategic alignment of Maintenance, Repair and Overhaul (MRO) operations. * Documentation and Compliance: Prepare detailed engineering documentation, including design specifications, checking and preparing drawings, testing procedures, and maintenance manuals. Ensure mechanical designs comply with relevant industry standards, safety regulations, and company policies. * Continuous Improvement: Stay informed about advancements in mechanical engineering and UAV technology, integrating best practices into analysis processes.   Competencies & Duties * Working independently and responsibly. Perform tasks as described above.  * Compliance according to ANAVIA’ employment contract, compliance with company’ safety instructions and employee’ safety requirements, compliance with employers’ quality manual, work instructions and corresponding process specifications and instructions. * International travel required up to 25% of employee’ working hours. YOUR PROFILE Qualifications * Education: Master’s degree in mechanical engineering, Aerospace Engineering, or a related field and (3) years of industry experience.  Doctoral degree is equivalent to industry experience. * Experience: 8+ years of systems engineering development experience. 5+ years in propulsion system design, integration, and test, preferably with gas or heavy fuel engines. A plus: experience with heavy fuel engines in maritime operations, and prior technical lead roles in UAV/aerospace projects. * Skills: * Knowledge of power and propulsion system and subsystem components such as fuel systems, propulsion-airframe integration, and ground equipment. * Proven experience managing vendor partnerships and cross-functional engineering teams. * Strong project management abilities (Agile, SCRUM, or similar frameworks). * Knowledge of DO-160, MIL-STD-461, or other aerospace environmental testing standards. * Communication: Very good communication skills. High social skills and good analytical and excellent technical understanding. * Language: Good language skills in English (oral and written). German desirable. * Passport: Swiss / EU Nationals only.