Maintenance Manager
Mechanical | Electrical | Utilities | PLC | SCADA | Reliability Engineering
Company: JC Global
Location: Gummidipoondi
Industry : Recycling / Chemical Recycling Industry / Hazardous Industry
Willing to Implement system in other units in Ganeshapuram, Coimbatore (Travel to other manufacturing units as required)
Reporting To: Plant Head
About JC Global
JC Global is a fast-growing circular economy manufacturing company engaged in the production of recycled polymer granules and sustainable recycling solutions. We are looking for a technically strong Maintenance Manager to lead preventive, predictive, and breakdown maintenance while driving equipment reliability, automation, safety, and operational excellence across the manufacturing plant.
Position Summary
The Maintenance Manager will be responsible for ensuring maximum plant uptime, implementing world-class maintenance systems, managing PLC/SCADA-based automation, maintaining critical spare inventories, improving Overall Equipment Effectiveness (OEE), and ensuring statutory and EHS compliance.
The role requires hands-on experience in plastic/polymer processing or continuous manufacturing industries.
Key Responsibilities1. Plant Maintenance
- Lead preventive, predictive, breakdown, and corrective maintenance activities.
- Ensure maximum equipment availability and plant uptime.
- Reduce machine breakdowns through root cause analysis and corrective actions.
- Develop annual and monthly maintenance plans.
- Ensure zero production loss due to maintenance failures.
2. Preventive & Predictive Maintenance
- Prepare preventive maintenance schedules for all plant equipment.
- Develop equipment history cards and maintenance logs.
- Monitor maintenance KPIs such as MTBF, MTTR, and downtime.
- Introduce condition-based and predictive maintenance practices.
- Ensure timely calibration of equipment.
3. PLC, SCADA & Automation
- Strong knowledge of PLC and SCADA systems.
- Diagnose PLC and automation-related faults.
- Monitor machine performance through SCADA dashboards.
- Coordinate PLC programming modifications with automation vendors.
- Ensure proper backup of PLC and HMI programs.
- Improve automation for productivity and reliability.
- Maintain machine communication networks and industrial I/O systems.
4. Utilities & Plant Equipment
Maintain and monitor:
- Extrusion lines
- Material handling systems
- Cooling towers
- Chillers
- Air compressors
- DG sets
- Electrical panels
- Transformers
- HT/LT systems
- Pumps and motors
- Conveyors
- Weighing systems
- Fire hydrant systems
- Utility pipelines
5. Spare Parts & Inventory Management
- Maintain complete critical spare parts inventory.
- Define minimum, maximum, and re-order levels for all maintenance spares.
- Monitor stock availability to prevent production stoppages.
- Maintain spare consumption history.
- Identify obsolete and slow-moving inventory.
- Coordinate with Stores and Purchase for timely procurement.
- Standardize spare parts across machines where feasible.
6. Vendor Management
- Develop and evaluate maintenance vendors and service providers.
- Coordinate AMC contracts and emergency service support.
- Negotiate pricing and service agreements.
- Evaluate vendor performance.
- Ensure timely completion of outsourced maintenance activities.
7. Plant EHS & Compliance
- Ensure safe maintenance practices and permit-to-work compliance.
- Conduct machine safety inspections.
- Ensure Lockout/Tagout (LOTO) procedures are followed.
- Participate in hazard identification and risk assessments.
- Maintain statutory records related to maintenance.
- Support ISO 9001, ISO 14001, ISO 45001, IMS, and ESG compliance.
- Participate in fire drills and emergency preparedness programs.
8. Reliability & Continuous Improvement
- Perform Root Cause Analysis (RCA) for major breakdowns.
- Implement CAPA for recurring failures.
- Improve OEE and equipment reliability.
- Reduce maintenance costs through process improvements.
- Lead Kaizen and TPM initiatives.
- Implement energy-saving projects.
9. Documentation & MIS
- Maintain maintenance SOPs and work instructions.
- Prepare daily, weekly, and monthly maintenance reports.
- Maintain equipment manuals, drawings, and service records.
- Track maintenance KPIs and present dashboards to management.
- Maintain maintenance budget and expenditure records.
10. Team Leadership
- Lead maintenance engineers, technicians, electricians, and fitters.
- Allocate daily work and monitor completion.
- Conduct toolbox talks and technical training.
- Develop team competency and succession plans.
- Ensure 24x7 maintenance support for plant operations.
Key Performance Indicators (KPIs)
- Plant uptime (%)
- Equipment availability
- Preventive maintenance compliance (%)
- Breakdown frequency
- Mean Time Between Failures (MTBF)
- Mean Time to Repair (MTTR)
- OEE improvement
- Critical spare availability
- Maintenance cost per ton
- Energy efficiency improvements
- Zero safety incidents
- Audit compliance score
- Vendor performance
- Maintenance schedule adherence
Desired Candidate ProfileMandatory Requirements
- BE/B.Tech in Mechanical or Electrical Engineering.
- 8–15 years of maintenance experience in a manufacturing industry.
- Experience in plastic, polymer, recycling, chemical, process, FMCG, or engineering manufacturing preferred.
- Strong knowledge of PLC, SCADA, industrial automation, electrical systems, and utilities.
- Experience with preventive and predictive maintenance systems.
- Knowledge of CMMS/ERP maintenance modules is an advantage.
- Familiarity with ISO, IMS, EHS, and statutory compliance.
- Strong leadership, troubleshooting, and vendor management skills.
- Willingness to travel to other JC Global manufacturing units when required.
Preferred Technical Skills
- PLC troubleshooting (Siemens, Allen-Bradley, Mitsubishi, Delta, Omron, etc.)
- SCADA monitoring and diagnostics
- VFDs, HMIs, sensors, instrumentation
- Pneumatic and hydraulic systems
- Electrical distribution systems
- Root Cause Analysis (RCA)
- Failure Mode and Effects Analysis (FMEA)
- Total Productive Maintenance (TPM)
- Lean Manufacturing and Kaizen
- Predictive maintenance tools (vibration, thermography, oil analysis)
Salary 50000 onwards per month based on experience
Pay: From ₹50,000.00 per month
Work Location: In person
