Maintenance, TPM

Job Purpose:

To lead, plan, and manage all mechanical and electrical maintenance activities to ensure optimal equipment performance, minimal downtime, and maximum reliability of plant and machinery. The role involves preventive and predictive maintenance, resource management, and continuous improvement initiatives to support production efficiency and safety standards.

Key Responsibilities:

1. Maintenance Planning & Execution

• Develop and implement preventive and predictive maintenance schedules for all mechanical equipment and utilities.

• Ensure timely execution of breakdown maintenance with minimal production interruption.

• Monitor equipment health and performance through CMMS or other maintenance tools.

• Coordinate shutdown maintenance, overhauls, and annual turnarounds.

1. Team Leadership & Supervision

• Lead, train, and motivate the mechanical maintenance team to achieve departmental objectives.

• Ensure skill enhancement and succession planning for technicians and engineers.

• Maintain a culture of accountability, discipline, and continuous improvement.

1. Equipment Reliability & Performance

• Identify chronic issues and implement root cause analysis (RCA) and corrective actions.

• Implement reliability-centered maintenance (RCM) and failure mode analysis (FMEA).

• Review and optimize spare parts inventory and ensure cost control.

1. Projects & Modifications

• Support plant modifications, equipment upgrades, and new project installations.

• Coordinate with design, procurement, and operations teams for mechanical projects.

• Ensure all installations comply with safety, quality, and engineering standards.

1. Safety & Compliance

• Ensure adherence to all statutory, safety, and environmental regulations.

• Conduct safety audits, risk assessments, and implement CAPA for incidents.

• Promote safety-first culture within the maintenance team.

• Working environment in ISO 9001,45001 and 14001 with all documents preparation.

• Must have faced above IMS audits.

1. Documentation & Reporting

• Maintain maintenance records, downtime analysis, and performance KPIs.

• Prepare and present monthly reports on maintenance performance, cost, and reliability metrics.

• Utilize SAP/CMMS systems for maintenance planning and tracking.

Key Skills & Competencies:

• Strong technical knowledge of mechanical systems: pumps, compressors, conveyors, gearboxes, hydraulics, pneumatics, etc.

• Hands-on experience with preventive, predictive, and condition-based maintenance.

• Leadership, communication, and team management skills.

• Knowledge of TPM (Total Productive Maintenance) and Lean principles.

• Proficiency in MS Office and maintenance management software (SAP / Maximo / CMMS).

• Problem-solving and decision-making under pressure.

Educational Qualification:

• B.E. / B.Tech in Mechanical Engineering (preferred)

• Additional certifications in Maintenance Management, TPM, or Reliability Engineering are desirable.

Performance Metrics:

• Equipment uptime and OEE (Overall Equipment Effectiveness)

• Reduction in breakdown frequency and MTTR (Mean Time to Repair)

• Adherence to maintenance budget and cost savings achieved

• • Implementation of safety and compliance standards