Senior Manager - Maintenance

Manager Maintenance

Department: Maintenance
Industry: Heavy Auto Component Machining & Engineering
Location: Vayalur
Reporting To: Plant Head / Operations Head

Job Summary

The Manager – Maintenance will be responsible for planning, organizing, and controlling all maintenance activities of heavy machining equipment and plant utilities to ensure maximum equipment uptime, reliability, safety, and cost efficiency. The role involves preventive, predictive, and breakdown maintenance management in a high-volume auto component manufacturing environment.

Key Responsibilities

1. Maintenance Planning & Execution

• Develop and implement preventive, predictive, and corrective maintenance programs.
• Ensure minimum downtime of CNC machines, VMCs, HMCs, grinding machines, special purpose machines (SPMs), and heavy engineering equipment.
• Monitor machine performance and implement corrective actions.
• Maintain MTBF (Mean Time Between Failures) and reduce MTTR (Mean Time To Repair).

2. Breakdown Management

• Lead quick response teams for machine breakdowns.
• Conduct root cause analysis (RCA) for major failures.
• Implement corrective and preventive action (CAPA).

3. Utilities & Infrastructure Maintenance

• Oversee maintenance of compressors, chillers, transformers, HT/LT panels, DG sets, EOT cranes, cooling towers, and hydraulic systems.
• Ensure uninterrupted power and utility supply.

4. Team Management

• Lead and supervise maintenance engineers, technicians, and contract workforce.
• Allocate tasks and ensure skill development and training.
• Maintain discipline and safety standards within the department.

5. Spare Parts & Inventory Control

• Monitor and control maintenance stores and critical spares.
• Optimize spare inventory cost.
• Coordinate with procurement for timely availability of parts.

6. Continuous Improvement

• Drive TPM (Total Productive Maintenance) initiatives.
• Implement 5S, Kaizen, and Lean maintenance practices.
• Improve machine efficiency and reduce maintenance cost.

7. Safety & Compliance

• Ensure compliance with statutory and safety regulations.
• Conduct safety audits and ensure safe work practices.
• Maintain documentation as per ISO/TS/IATF standards.

8. Budgeting & Cost Control

• Prepare and manage annual maintenance budget.
• Control maintenance expenses without affecting performance.

Key Performance Indicators (KPIs)

• Machine uptime percentage
• Breakdown frequency
• MTBF & MTTR
• Maintenance cost vs budget
• Spare inventory turnover
• Safety compliance

Qualifications & Experience

Education:

• B.E / B.Tech in Mechanical / Electrical Engineering
• Diploma with strong experience may also be considered

Experience:

• 8–15 years in maintenance of heavy machining / auto component industry
• Minimum 3–5 years in managerial role

Required Skills

• Strong knowledge of CNC machinery and heavy engineering equipment
• Expertise in hydraulics, pneumatics, PLC systems
• Knowledge of TPM, Lean Manufacturing
• Root cause analysis skills
• Strong leadership and team management abilities
• Budgeting and cost control
• Excellent problem-solving skills

Preferred Experience

• Experience in IATF 16949 certified automotive industry
• Exposure to SAP / ERP maintenance modules
• Knowledge of predictive maintenance tools (vibration analysis, thermography)