Maintenance Head

Position: Maintenance Head (Reports to Plant Head)

Experience: 10+years in manufacturing, out of which 5+ years as Maintenance Head.

Qualification: BE Mech/Electrical 10+ Years of experience, DME(Mech/Elec) 15+ Years of experience.

Job Purpose: Define strategy, set systems and procedures, create budget and ensure that the production facilities and other sections of the plant are maintained at optimum efficiency to ensure planned production, while controlling costs and maintaining highest standards of quality and safety for man and machine.

Key Responsibility:

Preventive & Breakdown Maintenance:

• Create preventive maintenance schedules for presses, welding machines, bending/forming tools, and utilities.

Machine Health & Spare Parts:

• Maintain asset history and breakdown logs.
• Ensure availability of critical spare parts and maintain reordering levels.

Electrical & Automation:

• Oversee panel wiring, VFD/PLC maintenance, and troubleshooting electrical faults in automation equipment.
• Support welding automation, robotic arms, and vision-based inspection systems.

Utilities & Infrastructure:

• Maintain compressors, generators, cranes, HVACs, DG sets, and ensure energy-efficient operations.
• Ensure electrical safety audits and compliance with statutory norms (Factory Act, ISO

Systems & Procedures:

• Understand organizational objectives, short-term and long-term goals, and develop a maintenance strategy in line with these objectives.
• Plan, document, and communicate well-defined Standard Operating Procedures (SOPs) for predictive, preventive, and breakdown maintenance, in line with the maintenance strategy with an objective of achieving zero downtime.
• Ensure maintenance as well as other related personnel are aware of the SOPs and are kept updated on changes made from time to time.
• Evaluate the SOPs periodically and ensure learnings are captured in subsequent revisions.
• Provide expert technical advice on all aspects of engineering to other managers and staff to ensure effective decision-making.
• Define systems and guidelines for Engineering Stores, along with the Plant Head and Sectional Heads.

Maintenance Planning:

• Develop predictive and preventive maintenance schedules for plant, machinery, and equipment to ensure that these continue to operate at optimum levels.
• In coordination with the Plant Head and Production Head, freeze these plans and communicate the same on a need-to-know basis.
• Study historical breakdowns, analyze the root cause, and plan actions to eliminate the root cause.

Preventive & Predictive Execution and Monitoring:

• Monitor predictive and preventive maintenance work to ensure that it is carried out to the required standard and within agreed budget levels.
• Monitor and revise predictive and preventive maintenance schedules as necessary to ensure their continued effective performance.
• Guide and mentor the maintenance team to ensure operational goals are achieved and there is zero breakdown downtime.
• Guide and mentor the operations team to identify incidents indicative of potential breakdowns and empower them to raise alerts as and when these incidents are observed.

Safety & Environment:

• Ensure the safety of all personnel, equipment, and facilities through administration of programs, modeling safety at all times, and instilling the value of personal responsibility for safety in each individual.
• Ensure compliance with all safety procedures without exception.
• Participate in regular and refresher training on safety procedures.
• Ensure environmental norms are understood and captured in workflows.
• Ensure that the team is aware of all pollution control needs and compliance requirements.

Business Plan:

• Understand the Annual Business Plan, goals, and targets of your function.

Budget & Cost Control:

• Use optimally, monitor, and control the functional budget for the year. Adhere to policies to control cost.
• Record data and variance against budget items assigned to your function.
• Ensure compliance with defined procedures and use of related formats and checklists in all areas of work.
• Record data and variance against budget items assigned to your function.

Standard Operating Procedures:

• Ensure compliance with defined procedures and use of related formats and checklists in all areas of work.

Reports & MIS:

• Capture data your role is responsible for in defined formats. Ensure accuracy and timely submission of each report.

Leadership: Clarity of communication, Team Building, Motivation, Counselling.

Managerial:

• Budgeting, Data-based decision making, Continuous Improvement, Cost Control, MIS, and process orientation.
  
  Planning, organizing, scheduling, and monitoring.
  
  Problem analysis and problem-solving.
  
  Delegation.
  
  Ability to prioritize between predictive, preventive, and breakdown maintenance.

Functional:

Knowledge of high-volume, precision, close-tolerance production technology, and manufacturing processes.

Knowledge of preventive, predictive, and breakdown maintenance planning and execution.

Exposure to TPM/TQM/ISO/TS16949 quality assurance systems and standards.

Understanding of automobile parts and their functioning in an automobile.

Technological:

Capability to use Microsoft Office, Intranet, and Internet/SAP.

Appreciation for use of technology to improve output and performance.