Plan, execute and monitor preventive, predictive and breakdown maintenance activities for API manufacturing equipment. Ensure maximum availability and reliability of critical process equipment. Troubleshoot recurring mechanical, electrical, instrumentation and utility-related failures. Conduct breakdown analysis and implement effective corrective and preventive actions. Maintain equipment history cards, maintenance records, checklists and logbooks. Monitor maintenance performance through MTBF, MTTR, equipment availability and downtime. Plan and execute annual maintenance shutdowns, major equipment overhauls and turnarounds. Coordinate with Production, QA, EHS and other departments for maintenance activities. 2. API Process Equipment Ensure proper maintenance of equipment such as: Reactors and agitators Centrifuges ANFD / dryers Vacuum systems Pumps and mechanical seals Filters and filtration systems Heat exchangers Storage and process vessels Compressors Gearboxes and drives Piping, valves and associated process equipment 3. Utility & Facility Maintenance Supervise maintenance and operation of critical plant utilities, including: HVAC / AHU systems Chillers and cooling towers Boilers and steam distribution Compressed air systems Vacuum systems RO / DM / Purified Water systems Nitrogen systems ETP / STP and other utility systems Electrical distribution systems DG sets and power backup systems Fire-fighting and other facility systems Ensure utility parameters are maintained within approved operating limits and applicable SOP requirements. 4. GMP & Regulatory Compliance Ensure all maintenance activities are performed in accordance with cGMP, SOPs, EHS requirements and Good Engineering Practices (GEP). Maintain complete and accurate engineering documentation. Support internal, customer and regulatory audits. Ensure timely closure of engineering-related observations, deviations, CAPA and change controls. Participate in equipment and utility qualification / validation activities. Support preparation and review of URS, DQ, FAT, SAT, IQ, OQ and PQ documents wherever applicable. Ensure maintenance records comply with Good Documentation Practices and data-integrity requirements. 5. Reliability & Continuous Improvement Identify chronic equipment failures and conduct Root Cause Analysis (RCA). Implement reliability improvement initiatives to reduce breakdowns and maintenance costs. Introduce predictive maintenance techniques such as vibration monitoring, thermography, condition monitoring and oil analysis where applicable. Identify opportunities for energy conservation and utility optimization. Drive TPM / Lean maintenance practices and equipment reliability improvements. Review maintenance trends and develop improvement plans. 6. Spare Parts & Vendor Management Identify and maintain adequate stock of critical engineering spares. Develop critical spare-parts lists based on equipment criticality. Coordinate with Purchase and Stores for timely procurement. Evaluate vendors and service providers from a technical perspective. Coordinate AMC, equipment servicing and specialist maintenance activities. Ensure proper control and traceability of engineering materials and spares. 7. Projects & Modification Support engineering projects, plant modifications, capacity expansion and equipment upgrades. Review technical specifications, drawings and vendor proposals. Coordinate installation, commissioning and qualification of new equipment. Ensure projects are executed safely, within approved budget and timelines. Support change-control implementation for engineering modifications. 8. Budget & Cost Control Assist in preparation of annual maintenance budgets. Monitor maintenance expenditure and identify cost-reduction opportunities. Control repair, AMC, spare-part and contractor costs. Support CapEx proposals for equipment replacement, upgrades and new projects. 9. Team Management Lead and supervise engineers, technicians, operators and contract manpower. Allocate daily maintenance jobs and monitor execution. Conduct technical training and competency development programs. Ensure adherence to safety procedures, PPE and work-permit systems. Develop a technically competent and responsive maintenance team. Coordinate shift / emergency support for critical breakdowns. Key Performance Indicators (KPIs) Equipment availability / uptime Reduction in breakdown frequency MTBF improvement MTTR reduction Preventive maintenance compliance Breakdown maintenance closure Critical spare availability Utility reliability Maintenance cost reduction Energy consumption
