Manager - Maintenance

Responsibilities & Key Deliverables

Role Purpose

Enhancing equipment uptime with optimum maintenance cost and robust maintenance planning, including MFMEA’s, RCA’s. Implementation of maintenance strategies to ensure the safe, efficient, and high-quality production. Designing and implementing new manufacturing technologies & processes for assembly, laser welding and testing, including tooling, jigs, and fixtures.

Key Roles & Responsibilities

• Planning, scheduling, and executing preventive, predictive, and breakdown maintenance for various production equipment such as CNC machines, assembly lines, welding robots, and more.
• Collaborating closely with production and engineering teams to efficiently minimize equipment downtime and optimise productivity.
• Troubleshooting mechanical, electrical, and automation-related issues on production machinery promptly and effectively.
• Ensuring the timely availability of critical spare parts and maintenance tools necessary for operational continuity.
• Managing the complete documentation process in accordance with IATF16949, ISO 14001:2015, and ISO 45001:2018 to uphold the highest standards of quality management.
• Utilising hands-on skills in PLC programming and a deep understanding of machine functionalities while addressing troubleshooting for various manufacturing assembly lines.
• Proactively leading initiatives aimed at enhancing Product Quality, Cost, Delivery, Safety, and Morale (P Q C D S M) metrics within the manufacturing unit.
• Executing all statutory and legal testing activities, both internal and external, ensuring full compliance with relevant regulations.
• Focusing on energy and water conservation initiatives as part of sustainable manufacturing practices.
• Monitoring and controlling spare part usage and repair costs to ensure effective budget management.
• Implementing comprehensive lubrication management practices for all machinery and equipment, ensuring longevity and optimal functionality.
• Staying abreast of statutory and legal requirements as outlined under the factories act and ensuring adherence at all levels.

Key Deliverables

• Achieve year-on-year maintenance cost reduction through preventive maintenance, spares optimization, and energy-saving initiatives.
• Ensure maximum equipment availability to support production capacity targets with minimal unplanned downtime.
• Implement Digital systems and Level‑3 Poka‑Yoke solutions to prevent repeat failures, human errors, and customer complaints.
• Improve customer focus and Direct-to-Delivery (D2D) performance by ensuring zero breakdowns at critical customer-impacting processes.
• Optimize Repair & Maintenance (R&M) costs by lifecycle-based maintenance planning and vendor cost rationalization.
• Lead digitization of maintenance activities including breakdown reporting, preventive maintenance tracking, and spares management.
• Reduce efficiency loss in all aggregates operations by identifying chronic breakdowns and executing permanent corrective actions.
• Establish contingency plans and de-bottlenecking solutions for critical equipment and production stages to avoid line stoppages.
• Ensure 100% equipment readiness for new product launches, including trials, validations, and ramp-up support.
• Drive Manufacturing Excellence by improving MTBF (Mean Time Between Failures) and reducing MTTR (Mean Time To Repair).
• Strengthen process quality by eliminating recurring defects linked to equipment issues and improving process capability.

Experience

• A minimum of 12 to 15 years of hands-on experience in maintenance within a manufacturing setting, particularly focused on complex machinery.
• A track record of effectively coordinating maintenance activities in a fast-paced, production-oriented environment.
• Robust troubleshooting skills, with the ability to solve mechanical, hydraulic, electrical, and pneumatic problems effectively.
• Familiarity with advanced maintenance management systems and tools, translating to improved operations and reduced downtime.

Industry Preferred

•    Automobile - Original Equipment Manufacturer (OEM)
•    Manufacturing of Electrical and Electronic products
•    Assembly Line Production Facilities

Qualifications

Bachelor's degree in Electrical & Electronics Engineering (EEE)

General Requirements

• Hands-on experience with ISO documentation including IATF, EHS, and OHSAS regulations.
• Familiarity with SAP plant maintenance modules to facilitate streamlined operations.
• A valid electrical inspectorate certificate along with an up-to-date electrical license.
• An understanding of basic safety protocols and procedures, including the handling of legal documentation.
• Knowledge of safety standards and the effective usage of activity-based Personal Protective Equipment (PPE), employing methodologies such as TPM and 5S.
• Proven ability to spearhead improvement initiatives and preparation of Kaizen plans.
• Capability to manage breakdowns of machinery across various systems, employing analytical skills for problem-solving and corrective actions.
• Experience with planned maintenance activities, with a strong emphasis on preventive and predictive methodologies.
• Flexibility to work in shifts and manage on-shift technicians efficiently.
• Capability to identify machine spares and adeptness at inventory management to ensure operational readiness.
• A thorough understanding of repair and maintenance cost structures, with a focus on cost reduction strategies.
• Team handling experience
• Competence in reading and interpreting electrical, pneumatic, hydraulic, and mechanical drawings for precise maintenance activities.

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