Maintenance Engineer Manager

Position:
Maintenance Engineer / Maintenance Lead

Industry Preference:
FMCG / Food Processing / Beverage / Pharma / Manufacturing

Location:
Bareilly

Joining Timeline:
Within 30 days (Ideal: within 15 days)

Role Overview:

We are seeking a highly capable and hands-on
Maintenance Engineer
 with strong exposure to
plant operations
, preferably from the
FMCG or continuous-process manufacturing industry
.

The ideal candidate will drive
machine reliability, zero-breakdown culture, preventive/predictive maintenance, and continuous improvement initiatives
 such as TPM, Kaizen, Poka-Yoke, MTTR/MTBF improvement, and energy-saving projects.

This role demands strong ownership, on-ground troubleshooting skills, and close coordination with production teams to ensure 100% uptime and operational efficiency.

Key Responsibilities:

1. Preventive, Predictive & Planned Maintenance Excellence

2. Develop and execute monthly/quarterly
   Preventive Maintenance (PM)
    schedules aligned with production needs.

3. Implement
   Predictive Maintenance
    using condition monitoring techniques.
4. Continuously improve machine reliability through
   MTTR, MTBF, MRT
    analysis.
5. Ensure revision and optimization of PM schedules based on recurring issues.

2, Breakdown & Root Cause Management

• Lead urgent machine breakdowns with hands-on troubleshooting.
• Perform
  RCA (Root Cause Analysis), Why–Why Analysis, and CAPA implementation
  .
• Ensure breakdown does not repeat through SOP updates, training, and design improvements.
• Maintain an effective
  Zero Breakdown culture
  .

3, Continuous Improvement: TPM, Kaizen, & Poka-Yoke

• Actively participate in and lead
  TPM pillars
  , including Autonomous & Planned Maintenance.
• Execute
  Kaizen projects
   to enhance machine performance and reduce downtime.
• Implement
  Poka-Yoke solutions
   to prevent process and equipment errors.
• Track improvements through measurable KPIs (downtime, energy usage, reliability).

4, Spare & Inventory Management

• Maintain optimum stock of critical spares and consumables.
• Implement engineering inventory management systems ensuring
  zero stockouts
  .
• Improve spare parts consumption visibility through FIFO and traceability systems.

5, Machine efficiency and Energy Saving Projects

• Improve equipment availability and performance through
  MTTR/MTBF analysis
  .
• Work on
  energy-saving projects
   such as compressor optimization, panel load balancing, and utility efficiency improvement.
• Track equipment health through performance dashboards and energy meters.

6, Reporting, Tracking, & Documentation

• Develop and maintain
  daily/weekly/monthly maintenance trackers
  .
• Present dashboards covering downtime, chronic issues, maintenance cost, MTTR, MTBF.
• Maintain complete documentation for audits, compliance, and TPM reviews.

7, Coordination with Production

• Plan maintenance activities around production schedules to minimize downtime.
• Support production operations during peak loads and emergency conditions.
• Ensure strong communication and collaboration with production and QA teams.

Skills Required:

• Must have 5+yrs of relevant Experience in FMCG/Manufacturing/Plant Operations.
• Hands-on experience in
  electrical panels, compressors, motors, pumps, conveyors, utilities
  .
• Strong practical troubleshooting skills in mechanical & electrical systems.
• Experience in
  TPM, Kaizen, Poka-Yoke, 5S, and Continuous Improvement
  .
• Proficiency in maintenance metrics:
  MTTR, MTBF, MRT, downtime analysis
  .
• Knowledge of energy-saving techniques in industrial environments
• Strong understanding of
  preventive & predictive maintenance systems
  .