Maintenance Supervisor

Job Objective : To lead the plant maintenance function by ensuring high equipment availability, reliability, and operational efficiency through effective preventive and predictive maintenance, TPM implementation, technical troubleshooting, and continuous cost optimization. The candidate should possess strong hands-on knowledge of PLC, electrical, mechanical, and automation systems, along with proven experience in managing maintenance teams, handling critical equipment breakdowns, and supporting new production line installation and ramp-up.

Key Responsibilities

Maintenance Operations & Team Management - Lead and manage a maintenance team of at least 15 technicians and engineers. Ensure smooth execution of daily maintenance activities across production lines. Plan and monitor preventive, predictive, and breakdown maintenance activities. Ensure minimum equipment downtime and maximum machine availability. Handle critical breakdowns independently and provide permanent technical solutions. Develop maintenance schedules, manpower allocation, and shift-wise maintenance plans.

Technical Expertise Electrical, Mechanical & Automation -Hands-on troubleshooting experience in PLC-controlled machines. Strong knowledge of PLC systems, preferably Siemens, Mitsubishi, Omron, or Allen-Bradley. Electrical troubleshooting of motors, drives, VFDs, servo systems, sensors, control panels, and industrial wiring. Mechanical troubleshooting involving gearboxes, bearings, pneumatic and hydraulic systems, actuators, conveyors, and transmission systems. Experience in PU foaming machines, dosing systems, mixing systems, temperature control, and associated automation. Experience in glass handling systems, including conveyors, lifting mechanisms, transfer systems, glass positioning, and automated handling equipment. Ability to identify root causes and implement permanent corrective and preventive actions.

TPM & Maintenance Excellence -Lead implementation of Total Productive Maintenance (TPM).Implement autonomous maintenance and planned maintenance activities. Drive improvement in MTBF, MTTR, equipment availability, and OEE. Conduct Root Cause Analysis (RCA), 5 Why, Fishbone Analysis, and FMEA. Develop and standardize maintenance SOPs, checklists, inspection formats, and troubleshooting guides. Establish equipment history records and critical spare parts management systems.

New Production Line Installation & Ramp-up -Lead maintenance activities during installation and commissioning of new production lines. Coordinate with machine suppliers for installation, commissioning, and technical troubleshooting. Ensure equipment readiness before production trials and SOP. Support production teams in achieving targeted cycle time, productivity, and equipment availability during ramp-up. Develop preventive maintenance plans and spare parts lists for newly installed equipment. Handle technical coordination with Chinese machine manufacturers and suppliers.

Maintenance Cost Reduction & Optimization - Identify and implement cost-reduction opportunities in: Critical and consumable spare parts. Electrical energy consumption. Maintenance consumables and service expenses. External service and contractor costs. Value-added maintenance activities. Develop local alternatives for imported and high-cost spare parts wherever technically feasible. Optimize spare parts inventory without compromising equipment reliability. Drive machine life-extension initiatives and reduce recurring maintenance expenses. Establish and monitor annual maintenance budgets and cost-saving initiatives.

Supplier & Technical Coordination - Experience working directly with Chinese machinery suppliers. Coordinate with overseas suppliers for technical discussions, breakdown support, machine modifications, and commissioning. Review technical solutions and ensure effective implementation at the plant. Evaluate supplier proposals and identify technically and commercially viable solutions. Independently manage technical discussions and follow-ups with international suppliers.

Safety, SOP & Documentation - Ensure compliance with electrical and machine safety standards. Implement Lockout/Tagout (LOTO) and safe maintenance practices. Develop and maintain maintenance SOPs and equipment operating guidelines. Ensure compliance with statutory electrical safety requirements and C License responsibilities. Conduct regular technical training and skill development for maintenance personnel.

Mandatory Skills & Experience1 - 13 to 15 years of experience in industrial maintenance in an automated manufacturing environment. Valid C License with relevant electrical competency. Proven experience handling a minimum of 15 maintenance personnel. Strong hands-on knowledge of PLC, electrical, mechanical, and automation troubleshooting. Practical experience in TPM implementation Experience in PU foaming machinery and/or glass handling systems is highly preferred. Experience in new production line installation, commissioning, and ramp-up. Proven track record in maintenance cost reduction, spare parts optimization, and energy saving. Experience in handling Chinese machinery suppliers and overseas technical coordination. Strong problem-solving skills and ability to work under high-pressure manufacturing conditions.

Key Performance Indicators (KPIs) -Equipment availability and uptime. Reduction in breakdown hours and recurring failures. Improvement in MTBF and reduction in MTTR.TPM implementation and preventive maintenance compliance. Maintenance cost per unit of production. Spare parts cost reduction and inventory optimization. Electrical energy cost reduction. New line commissioning and ramp-up performance. Maintenance SOP implementation and audit compliance. Maintenance team productivity and technical competency development.