Deputy General Manager - Electrical- DRI

Key Responsibilities:-

1. Electrical Maintenance & Reliability

• Lead electrical maintenance activities across the DRI plant to ensure maximum equipment availability and minimum downtime.
• Ensure reliable operation of electrical systems associated with DRI production equipment.
• Plan and execute preventive, predictive, and breakdown maintenance activities.
• Monitor equipment health and identify recurring failures and reliability issues.
• Drive Root Cause Analysis (RCA) for major and repetitive electrical breakdowns.
• Develop and implement corrective and preventive actions to improve equipment reliability.
• Ensure timely maintenance of critical electrical equipment and maintain adequate critical spares.

2. Electrical Systems & Equipment

• Manage maintenance of HT/LT electrical systems, transformers, switchgear, MCCs, PCCs, motors, VFDs, control panels, cables, DG sets, UPS systems, battery systems, and protection systems.
• Ensure proper functioning and maintenance of electrical distribution systems across the plant.
• Oversee maintenance of electrical systems related to DRI kilns, material handling systems, fans, blowers, conveyors, compressors, pumps and utility systems.
• Monitor electrical parameters, power quality, load distribution and system performance.
• Ensure proper coordination with production and other maintenance functions for planned shutdowns and equipment interventions.

3. Maintenance Planning & Shutdown Management

• Prepare and monitor annual, monthly and weekly electrical maintenance plans.
• Lead electrical activities during planned plant shutdowns and major maintenance jobs.
• Ensure availability of manpower, tools, equipment, consumables and spares before shutdown activities.
• Review shutdown performance, identify gaps and implement improvement actions.
• Minimize maintenance-related production losses through effective planning and execution.

4. Energy Management

• Monitor electrical energy consumption and identify opportunities for energy optimization.
• Drive initiatives for reduction of specific power consumption.
• Analyse major electrical loads and identify abnormal consumption patterns.
• Support implementation of energy-efficient motors, drives and electrical systems.
• Coordinate with relevant teams for power factor improvement and efficient utilization of electrical infrastructure.

5. Safety & Compliance

• Ensure strict compliance with electrical safety standards, statutory requirements and plant safety procedures.
• Ensure implementation of LOTO (Lockout/Tagout), electrical isolation and permit-to-work systems.
• Conduct periodic inspection of electrical installations and identify potential hazards.
• Ensure proper earthing, protection systems, cable management and electrical housekeeping.
• Drive safety awareness and safe working practices among maintenance employees and contractors.
• Ensure compliance with applicable electrical statutory inspections and audit requirements.

6. Team Leadership & People Management

• Lead, mentor and develop the electrical maintenance team.
• Allocate manpower effectively across shifts and maintenance activities.
• Set performance objectives and monitor team performance.
• Build technical capability through training, skill development and knowledge sharing.
• Promote a culture of ownership, discipline, safety and continuous improvement.

7. Vendor & Contractor Management

• Manage electrical maintenance contractors and service providers.
• Ensure contractors comply with plant safety and quality requirements.
• Evaluate contractor performance and ensure timely completion of assigned jobs.
• Coordinate with OEMs and external agencies for specialized electrical maintenance and troubleshooting.

8. Spare Parts & Cost Management

• Ensure availability of critical electrical spares to avoid prolonged equipment downtime.
• Review inventory levels, criticality and consumption trends.
• Control maintenance costs without compromising safety and equipment reliability.
• Support budgeting and CAPEX planning for electrical maintenance and improvement projects.
• Identify opportunities for cost reduction through repair, standardization and technology improvement.

9. MIS & Performance Monitoring

• Track key maintenance KPIs such as:
  
• Electrical equipment availability
• Breakdown hours and frequency
• MTBF / MTTR
• Preventive maintenance compliance
• Shutdown performance
• Energy consumption
• Maintenance cost
• Critical equipment reliability
• Prepare periodic maintenance reports and present key performance indicators to plant management.
• Maintain proper documentation of maintenance history, breakdown analysis and improvement initiatives.

Key Deliverables / KRAs

• Maximum electrical equipment availability and reliability.
• Reduction in electrical breakdown frequency and downtime.
• 100% adherence to preventive and predictive maintenance schedules.
• Reduction in MTTR and improvement in MTBF.
• Safe and reliable operation of HT/LT electrical systems.
• Effective shutdown planning and execution.
• Reduction in specific power consumption and electrical losses.
• Optimum utilization of maintenance manpower and resources.
• Effective control of electrical maintenance costs.
• Zero tolerance for critical electrical safety violations.

Educational Qualification

• B.E./B.Tech in Electrical Engineering from a reputed institution.
• Candidates with relevant postgraduate qualifications in Electrical/Power Engineering or Management may be preferred.

Experience:

• 15-20 years of relevant experience in electrical maintenance, preferably in DRI/Sponge Iron, Steel, Metallurgy, or other continuous/process manufacturing industries.
• Strong experience in handling electrical maintenance at a large-scale manufacturing plant.
• Experience in leading a sizeable electrical maintenance team is essential.
• Candidates with hands-on experience in HT/LT systems, transformers, switchgear, MCC/PCC, VFDs, motors, protection systems and industrial electrical distribution will be preferred.

Technical Competencies:

• Strong knowledge of industrial electrical systems and maintenance practices.
• Expertise in HT/LT distribution systems and electrical protection.
• Strong troubleshooting skills for motors, drives, switchgear and control systems.
• Knowledge of preventive and predictive maintenance methodologies.
• Good understanding of electrical safety and statutory compliance.
• Knowledge of PLC/automation interfaces and industrial control systems.
• Ability to analyse electrical failures using RCA and reliability engineering techniques.
• Knowledge of maintenance management systems such as SAP/CMMS is preferred.
• Strong understanding of energy management and electrical efficiency.

Behavioural Competencies:

• Strong leadership and team management.
• Decision-making and problem-solving ability.
• Ownership and accountability.
• Ability to work under pressure in a continuous-process plant environment.
• Strong coordination with Production, Mechanical, Instrumentation, Projects and Utilities teams.
• Good communication and stakeholder-management skills.
• Continuous improvement and result-oriented mindset.