Maintenance Manager

Position Purpose

The Maintenance Manager shall lead preventive, predictive, breakdown, utility, project, and energy management functions while ensuring minimum downtime and optimum maintenance cost.

Key Responsibilities

1. Plant Equipment Management

Responsible for maintenance and performance of all products machines and equipment

2. Preventive & Predictive Maintenance

• Develop annual preventive maintenance plans.
• Establish preventive maintenance schedules for all machines.
• Ensure preventive maintenance compliance above 95%.
• Introduce predictive maintenance techniques.
• Conduct vibration monitoring and thermal scanning.
• Implement lubrication management systems.
• Maintain equipment history records.

3. Breakdown Maintenance

• Ensure immediate response to machine breakdowns.
• Minimize production losses.
• Conduct Root Cause Analysis (RCA) of major failures.
• Implement corrective and preventive actions.
• Monitor MTBF and MTTR of critical equipment.

4. Utilities Management

Responsible for:

Electrical Systems

• HT/LT electrical installations
• Transformers
• PCC/MCC panels
• DG sets
• VFDs
• PLC systems

Refrigeration & Air Systems

• Air compressors
• Refrigeration units
• Chillers
• Air dryers

Process Utilities

• Pumps
• Blowers
• Exhaust systems
• Dust collection systems
• Hot air generators
• Drying systems

Monitor:

• Power consumption
• Compressed air efficiency
• Utility downtime
• Energy-saving initiatives

5. Engineering Projects

Lead projects related to:

• Capacity expansion
• Machine installation and commissioning
• Plant modernization
• Automation projects
• Utility optimization
• Energy-saving projects
• Factory infrastructure improvements

Prepare:

• Technical specifications
• Cost estimates
• Vendor evaluations
• Project implementation schedules

6. Spare Parts & Inventory Management

• Develop critical spare parts list.
• Maintain optimum inventory levels.
• Monitor spare consumption.
• Standardize commonly used components.
• Develop approved vendor list.
• Control maintenance budget.

7. Energy Management

Drive reduction in:

• Electrical consumption
• Compressor power consumption
• Drying system energy cost
• Water consumption

Implement:

• Waste heat recovery
• VFD applications
• Power factor improvement
• Solar energy initiatives
• Compressed air leak management

8. Safety & Compliance

Ensure compliance with:

• Factory Act requirements
• Electrical Safety Rules
• Fire Safety Standards
• Environmental Regulations
• Pollution Control Board requirements

Implement:

• LOTO procedures
• Permit-to-work systems
• Maintenance safety audits
• Contractor safety management

Target:

• Zero maintenance-related accidents

9. Continuous Improvement

Implement:

• TPM (Total Productive Maintenance)
• 5S
• Kaizen
• Lean Manufacturing

Drive:

• Downtime reduction
• Productivity improvement
• Maintenance cost optimization

10. Team Management

• Lead maintenance department across all shifts.
• Evaluate team performance.
• Prepare manpower planning.
• Ensure 24-hour maintenance coverage.