Senior Manager Maintenance

Job Description

POSITION TITLE: Sr. Manager-HOD of Maintenance

DIVISION / DEPARTMENT: Maintenance

REPORTS TO: Plant Head

LOCATION: Haridwar

POSITION SUMMARY:

The Head of Maintenance (HOD) leads and manages the Maintenance Department to ensure safe, reliable, efficient, and cost-effective operation of plant equipment, with a specific focus on coil coating lines (CCL). The role carries overall responsibility for planned and breakdown maintenance, predictive maintenance programs, spare parts strategy, equipment lifecycle management, safety and environmental compliance, and continuous improvement to maximize plant availability and product quality.

MAJOR RESPONSIBILITIES:

RESPONSIBILITIESStrategy & Leadership

1. Define and execute the maintenance strategy aligned with plant production targets and corporate objectives.
2. Lead, mentor, and develop the maintenance team (supervisors, engineers, technicians), promoting skills for CCL operations and general manufacturing.
3. Establish KPIs for availability, MTBF, MTTR, downtime, maintenance cost per tonne, and spare-part fill rate; monitor and report performance.

Coil Coating Lines (CCL) Expertise

1. Own technical maintenance for coil coating lines: pre-treatment, washing, chemical treatment, primer/top-coat application, ovens/burners, IR curing systems, cooling towers, recoilers/levellers, slitting & recoiling equipment, Roll Forming lines, Press brakes, Hot press, Glue Application machines and slitting lines and material handling conveyors.
2. Implement preventive and predictive maintenance (vibration analysis, thermography, oil analysis, laser alignment) specifically for CCL critical assets (oven/blower motors, drive systems, rollers, web handling, coating applicators).
3. Lead root cause analysis (5-why, fishbone, FMEA) for recurring failures in CCL and implement sustainable corrective actions.

Maintenance Planning & Execution.

1. Develop annual and short-term maintenance plans coordinated with production schedules (turnaround/shutdown planning).
2. Optimize spare parts inventory through criticality analysis and vendor agreements to minimize production risk.
3. Oversee external service providers and contractors for specialized maintenance, ensuring safety, quality, timelines, and cost control.

Reliability & Continuous Improvement

1. Drive reliability engineering initiatives: predictive maintenance roadmap, condition monitoring, CBM implementation, and OEE improvement.
2. Run structured CI projects (Kaizen, TPM, RCM) focusing on reducing unplanned downtime, improving process stability, and reducing maintenance costs.
3. Standardize maintenance procedures, checklists, and SOPs for CCL and associated systems.

Safety, Compliance & Quality

1. Enforce strict adherence to plant safety policies, lockout-tagout (LOTO), hot work permits, and environmental regulations.
2. Collaborate with QA/Process teams to ensure maintenance activities support product quality (coating thickness, adhesion, surface defects).

Maintain accurate maintenance records, compliance documentation, and audit readiness.

Budgeting & Vendor Management

1. Prepare and manage maintenance budget, CAPEX for replacements and upgrades, and evaluate ROI for equipment projects.

Negotiate service agreements, warranties, performance contracts, and manage relationships with OEMs and spares suppliers.

Reporting & Coordination

1. Provide regular reports to Plant Head/Management on maintenance KPIs, downtime root causes, and improvement plans.

Coordinate cross-functional activities with Production, Quality, Stores, and Procurement to ensure smooth operations.OTHER DUTIES AS ASSIGNED

QUALIFICATIONS

EDUCATION:

B.E./B.Tech in Mechanical/Electrical/Electronic/Instrumentation/Mechatronics. Additional qualification in Maintenance Management is a plus.


EXPERIENCE"

Minimum 10 - 15 years in maintenance roles within manufacturing; at least 5 years leading maintenance teams. Proven experience with coil coating lines, Roll Forming, Press brakes, Hot press, Glue Application machines and slitting lines, coating processes is essential.

AGE- 35-45 years


SPECIALIZED SKILLS:

Technical skills: Deep knowledge of CCL equipment (ovens, coating heads, burners, slitting), drives and PLC/SCADA systems, motors/drives/gearboxes, pneumatics/hydraulics, and instrumentation.

Soft skills: Strong leadership, communication, analytical problem-solving, vendor negotiation, project management, and ability to work under production pressures

SUPERVISION
The position has regular responsibility for overseeing or supervising the work of other employees and is responsible for decision making recommendations like hiring, promotion or termination*



HR Use Only:

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*** Age and Experience is based on eligibility and suitability.

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