Department Head

Job Description Sr. Manager / HOD Maintenance

Department: Maintenance

Location: Haridwar

Reports To: Plant Head

Position Summary

We are looking for a Sr. Manager / HOD Maintenance to lead the Maintenance function and ensure safe, reliable, efficient, and cost-effective operation of plant equipment.

The role will have a strong focus on Coil Coating Lines (CCL) along with other manufacturing equipment. The position will be responsible for preventive, predictive and breakdown maintenance, spare parts planning, equipment reliability, maintenance budgeting, safety compliance and continuous improvement.

Key Responsibilities

1. Maintenance Strategy & Team Leadership

• Develop and implement maintenance strategies aligned with production requirements.
• Lead and mentor maintenance engineers, supervisors and technicians.
• Define and monitor KPIs such as MTBF, MTTR, equipment availability, downtime and maintenance cost.
• Ensure effective manpower planning and skill development of the maintenance team.

2. Coil Coating Line (CCL) Maintenance

• Lead maintenance activities for Coil Coating Lines, including pre-treatment, washing, chemical treatment, primer/top-coat application, ovens/burners, IR curing systems, cooling systems, recoilers, levellers, slitting and recoiling equipment.
• Handle maintenance of Roll Forming Lines, Press Brakes, Hot Press, Glue Application Machines, Slitting Lines and material handling systems.
• Implement preventive and predictive maintenance for critical CCL equipment.
• Drive condition monitoring through vibration analysis, thermography, oil analysis and laser alignment.
• Conduct root cause analysis using 5 Why, Fishbone, FMEA and implement corrective actions.

3. Maintenance Planning & Execution

• Prepare annual, preventive and breakdown maintenance plans.
• Plan and execute shutdown/turnaround maintenance in coordination with Production.
• Ensure timely availability of critical spare parts through proper inventory planning.
• Manage external contractors and service providers while ensuring safety, quality, timelines and cost control.

4. Reliability & Continuous Improvement

• Drive reliability improvement, condition-based maintenance and OEE improvement initiatives.
• Implement TPM, Kaizen, RCM and other continuous improvement projects.
• Reduce unplanned downtime and improve equipment reliability.
• Develop and standardize maintenance SOPs, checklists and procedures.

5. Safety, Compliance & Quality

• Ensure compliance with plant safety procedures including LOTO and hot work permits.
• Ensure adherence to environmental and statutory requirements.
• Coordinate with Quality and Process teams to ensure maintenance activities support product quality.
• Maintain accurate maintenance records and ensure audit readiness.

6. Budget & Vendor Management

• Prepare and manage the maintenance budget and CAPEX requirements.
• Evaluate equipment replacement and upgrade proposals.
• Manage OEMs, vendors and spare-part suppliers.
• Negotiate service agreements, warranties and maintenance contracts.

7. Reporting & Coordination

• Report maintenance KPIs, downtime analysis, major breakdowns and improvement plans to the Plant Head/Management.
• Coordinate with Production, Quality, Stores and Procurement for smooth plant operations.
• Ensure timely closure of maintenance-related issues and improvement actions.

Education

• B.E./B.Tech in Mechanical / Electrical / Electronics / Instrumentation / Mechatronics.
• Additional qualification in Maintenance Management will be an advantage.

Experience

• 1015 years of overall experience in plant maintenance within a manufacturing environment.
• Minimum 5 years of experience in a maintenance leadership role.
• Strong hands-on experience with Coil Coating Lines (CCL) is essential.
• Experience with Roll Forming, Press Brakes, Hot Press, Glue Application Machines, Slitting Lines and coating processes is required.

Technical Skills

• Strong knowledge of CCL equipment, ovens, coating heads, burners and slitting systems.
• Good understanding of PLC/SCADA, motors, drives, gearboxes, pneumatics, hydraulics and instrumentation.
• Knowledge of preventive, predictive and breakdown maintenance.
• Experience in reliability improvement, RCA, TPM, Kaizen and condition monitoring.

Key Competencies

• Strong leadership and team management
• Analytical and problem-solving skills
• Vendor negotiation and management
• Project management
• Strong communication and coordination skills
• Ability to work effectively under production pressure

Age

35–45 years

Supervisory Responsibility

The role will have regular responsibility for supervising the Maintenance team and contributing to manpower-related decisions, including hiring, promotion and performance management.