General Manager-Mechanical

Job Summary

We are looking for an experienced and result-oriented Mechanical Maintenance & Reliability Leader to lead the Mechanical Maintenance, Reliability, Engineering and Project activities of our integrated paper mill.

The role will be responsible for ensuring high availability, reliability, safety and efficiency of a state-of-the-art, high-speed specialty-grade paper machine, fiber line, stock preparation and chemical recovery systems.

The incumbent will play a key role in building a proactive, reliability-driven maintenance culture, improving equipment performance and lifecycle cost, leading shutdowns and executing small and development projects.

Key Responsibilities

Mechanical Maintenance & Reliability

• Lead the complete mechanical maintenance and reliability function for the paper machine, fiber line, recovery plant and associated systems.
• Drive maximum equipment availability and reliability with minimum unplanned downtime.
• Develop and implement preventive, predictive and condition-based maintenance strategies.
• Establish equipment criticality-based maintenance plans and reliability improvement programs.
• Monitor and improve key KPIs including Mechanical Availability, MTBF, MTTR, Unplanned Downtime, Maintenance Cost/Ton, PM Compliance and Predictive Maintenance Compliance.
• Lead RCA, FMEA, RCM and structured problem-solving initiatives to eliminate recurring failures.
• Strengthen condition-monitoring practices including vibration analysis, thermography, oil analysis and ultrasound.
• Ensure reliability and mechanical integrity of critical rotating equipment, rolls, bearings, gearboxes, pumps, fans, compressors, agitators, drives and hydraulic systems.
• Lead annual shutdown planning and execution with focus on safety, quality, duration and cost.

Paper Machine Reliability

Provide mechanical reliability leadership for a high-speed specialty-grade paper machine covering:

• Forming, Press and Dryer sections
• Size Press / Sizer
• Calender, Reel and Winder
• Tail threading and vacuum systems
• Rolls, bearings, lubrication and hydraulic systems
• Doctor and felt/fabric-related mechanical systems
• Approach-flow and machine auxiliary systems
• Focus on improving machine speed, product quality, operational stability and reduction of mechanical-related web breaks and interruptions.

Fiber Line & Chemical Recovery

• Lead mechanical maintenance and reliability of fiber line and stock preparation systems including chippers, pulping, screening, refiners, cleaners, pumps, agitators, vacuum and filtration systems.
• Oversee mechanical reliability of chemical recovery and process equipment including evaporators, recovery boiler auxiliaries, causticizing, lime handling, heat exchangers, pressure equipment, pumps, fans, piping and material-handling systems.
• Drive improvements in reliability, energy efficiency, process stability and maintenance cost.

Engineering & Projects

• Identify and lead small, modification and development projects focused on capacity enhancement, reliability improvement, energy reduction and cost optimization.
• Prepare technical proposals, feasibility studies, specifications and preliminary estimates.
• Coordinate with Process, Production, Electrical, Instrumentation and Civil teams.
• Evaluate vendor proposals and manage procurement, fabrication, installation and commissioning.
• Ensure projects are delivered within approved scope, budget, quality and timelines.
• Conduct post-commissioning performance reviews and benefits realization.

Reliability & Continuous Improvement

• Develop and execute a long-term Mechanical Reliability Improvement Roadmap.
• Drive TPM, RCM, Kaizen and other continuous-improvement initiatives.
• Benchmark equipment performance against leading paper mills and industry best practices.
• Optimize critical spares and maintenance inventory based on equipment criticality and risk.
• Promote digitalization, data-driven maintenance and effective use of SAP PM / CMMS.
• Identify opportunities for improved machine speed, equipment life, energy efficiency and maintenance cost.

Safety & Mechanical Integrity

• Ensure compliance with plant safety standards and statutory requirements.
• Drive safe maintenance practices including LOTO, Permit-to-Work, confined-space work, hot work, work at height, lifting and rigging.
• Ensure periodic inspection and certification of pressure equipment, lifting equipment and other statutory systems.
• Maintain high standards of mechanical integrity and contractor safety.

Team Leadership

• Lead and develop a high-performing mechanical engineering and maintenance team.
• Establish clear KRAs, KPIs and competency development plans.
• Build internal capabilities in paper-machine maintenance, reliability engineering and condition monitoring.
• Mentor engineers and supervisors in RCA, predictive maintenance and modern reliability practices.
• Develop succession plans for critical technical positions.
• Foster a culture of ownership, accountability, innovation, safety and continuous improvement.

Qualification

• B.E./B.Tech in Mechanical Engineering from a reputed institution.
• M.Tech, MBA or certification in Reliability Engineering will be an added advantage.

Experience

• 18–25+ years of relevant experience in large process industries.
• Strong experience in Pulp & Paper, preferably within integrated paper mills.
• Proven exposure to high-speed paper machines, fiber line/stock preparation and chemical recovery systems.
• Experience in senior-level maintenance/reliability leadership.
• Strong experience in shutdown management, reliability improvement and engineering/project execution.