JOB DESCRIPTION
Senior Maintenance Manager :- Manufacturing
Department: Maintenance
Designation: Senior Maintenance Manager
Experience: 10–15 Years
Industry: Manufacturing / Engineering / Plastic / Auto Components / Industrial Manufacturing
Location:Umbergaon
Job Summary
To lead and manage the complete maintenance function of the manufacturing plant, ensuring maximum machine availability, minimum breakdowns, optimum maintenance cost, safe operations, and uninterrupted production. The position will be responsible for developing and implementing preventive, predictive and breakdown maintenance systems for plant machinery, utilities and infrastructure.
2. Key Responsibilities
* Maintenance Management
Develop and implement effective Preventive, Predictive and Breakdown Maintenance plans.
Ensure maximum availability and reliability of production machinery and equipment.
Monitor machine breakdowns, downtime, MTBF, MTTR and maintenance KPIs.
Analyse recurring breakdowns and implement permanent corrective actions.
Plan and execute annual maintenance schedules and shutdown activities.
Ensure timely maintenance of critical machines and equipment.
* Plant Machinery & Utilities
Handle maintenance of production machinery, electrical systems, mechanical systems, compressors, DG sets, pumps, HVAC, cooling systems and other plant utilities.
Ensure proper functioning and maintenance of electrical panels, motors, drives, PLCs, sensors and control systems.
Coordinate with production and other departments for planned maintenance activities.
Identify critical spare parts and maintain adequate inventory.
* Team Management
Lead, supervise and develop the maintenance team including engineers, technicians and contract manpower.
Allocate daily maintenance activities and monitor execution.
Conduct regular performance reviews and provide technical guidance to the team.
Develop training plans to improve technical capabilities and safety awareness.
* Cost & Spare Management
Prepare and control the maintenance budget.
Monitor maintenance expenses and identify cost-saving opportunities.
Ensure optimum utilization of manpower, spares, tools and external service providers.
Evaluate vendors and contractors for maintenance-related work.
Maintain proper records of spare parts consumption and inventory.
* Safety & Compliance
Ensure compliance with plant safety procedures and statutory requirements.
Implement safe maintenance practices, including LOTO (Lockout/Tagout) and permit-to-work systems.
Coordinate with EHS/HR/Administration teams for safety and statutory compliance.
Ensure proper documentation of maintenance activities, inspections and safety checks.
* Projects & Improvements
Support installation and commissioning of new machines and equipment.
Lead maintenance-related projects, machine modifications and improvements.
Identify opportunities for energy saving, automation, productivity improvement and reduction in breakdown costs.
Implement 5S, Kaizen, TPM and continuous improvement initiatives.
3. Key Performance Indicators (KPIs)
Reduction in machine breakdown frequency and downtime
Improvement in machine availability
Improvement in MTBF and MTTR
Achievement of preventive maintenance schedules
Reduction in maintenance cost
Optimum spare-parts inventory
Zero major maintenance-related safety incidents
Timely completion of maintenance projects
Improvement in equipment reliability and productivity
4. Qualification
Bachelor's Degree / Diploma in Mechanical or Electrical Engineering
Additional qualification in Maintenance Management / Industrial Engineering will be an advantage.
5. Experience & Skills
8–15 years of relevant experience in a manufacturing plant, preferably with 3–5 years in a managerial/senior maintenance role.
Strong knowledge of mechanical and electrical maintenance.
Experience in preventive, predictive and breakdown maintenance.
Strong troubleshooting and root-cause analysis skills.
Knowledge of PLC, VFD, electrical systems and industrial utilities.
Good understanding of TPM, 5S, Kaizen and continuous improvement.
Strong leadership, communication and team-management skills.
Good knowledge of maintenance planning, budgeting and spare-parts management.
Proficiency in MS Office and maintenance/ERP systems.
6. Preferred Candidate Profile
The ideal candidate should be a hands-on maintenance professional with strong technical knowledge and leadership capability. The candidate should have experience managing maintenance operations in a manufacturing environment and be capable of working closely with Production, Quality, EHS, Purchase and Administration teams to achieve plant objectives.
7. Core Competencies
* Leadership & Team Management
* Technical Troubleshooting
* Maintenance Planning
* Problem Solving & Root Cause Analysis
* Cost Control
* Decision Making
* Vendor Management
* Safety Awareness
* Continuous Improvement
* Production Coordination
The role requires regular presence on the shop floor and flexibility to attend critical machine breakdowns, plant shutdowns and emergency maintenance requirements whenever necessary.
Work Location: In person
