Mechanical Senior Manager - Material Resource Planning & Utility

Dual-charge role owning (a) material resource planning for the plant spares, consumables and engineering materials and (b) operation and maintenance of all plant utilities, ensuring uninterrupted utility supply at optimum cost.

Role & responsibilities

A. Material Resource Planning

• Own material planning for engineering spares, consumables, refractories, lubricants and general stores across the plant.
• Run the MRP cycle in SAP MM / ERP reorder points, min-max levels, safety stock, lead-time analysis, MRP runs and planned order conversion.
• Classify and govern inventory through ABC, VED, FSN and XYZ analysis; define critical and insurance spare lists jointly with maintenance heads.
• Drive inventory health — reduce non-moving, slow-moving and obsolete stock, improve inventory turns and control inventory carrying cost.
• Raise and track purchase requisitions; coordinate with Purchase, Stores and Finance on indent status, GRN, rejections and payment issues.
• Plan and secure long-lead and shutdown materials well ahead of planned shutdowns, relining and capital jobs.
• Prevent stock-outs of critical items; maintain and publish stock-out and material availability metrics.
• Maintain material master data, BOMs and equipment-spare linkages; drive standardisation and part-number rationalisation across departments.
• Support import planning, vendor development, alternate sourcing and spare indigenisation to reduce cost and dependency.
• Prepare the materials budget, track consumption against norms and analyse variances; support internal, statutory and cost audits.

B. Utilities

• Own operation and maintenance of all plant utilities — raw and process water systems, pump houses, cooling towers and closed-loop cooling circuits.
• Manage compressed air systems, air compressors, dryers and the plant air distribution network; drive reduction of leakages and specific air consumption.
• Manage DG sets, boilers, steam distribution, HVAC, ventilation, fume extraction and dust suppression systems as applicable.
• Operate and maintain the water treatment plant, effluent treatment plant and sewage treatment plant; ensure discharge parameters meet consent conditions.
• Own the plant water balance — sourcing, consumption norms, recycling and reuse, and zero-liquid-discharge initiatives where applicable.
• Maintain firefighting systems, hydrant network, pumps and fire water storage in a state of readiness.
• Drive energy and utility cost reduction — specific power, water and fuel consumption per tonne — through audits and improvement projects.
• Ensure statutory compliance for utilities — Boiler Act, pressure vessels, air receivers, pollution control board consents and periodic testing and certification.
• Plan and execute preventive maintenance, shutdown jobs and capital replacements for utility equipment.

Supervise utility shift teams, contractors and AMC vendors; enforce safety, work permit and LOTO discipline.

Preferred candidate profile

• Experience covering both material/spares planning and utility operations in a ferroalloy, steel, smelter, cement, chemical or comparable process plant.
• Strong hands-on capability in SAP MM and SAP PM (or an equivalent ERP/CMMS) — MRP runs, reservations, BOMs and work orders.
• Sound engineering understanding of pumps, compressors, cooling towers, boilers, water and effluent treatment systems.
• Advanced MS Excel and analytical skills; exposure to Power BI is desirable.
• Ability to work across Maintenance, Production, Purchase, Stores and Finance and to hold vendors to commitments.
• Candidates with a strong background in only one of the two areas may be considered if they demonstrate clear capability to take on the other.