Senior Manager - Plant Engineering & Maintenance

Position Title: Head - Plant Engineering & Maintenance (Kalwa Works)

Organization : SI EP IAA MF&Q KW

Location: Kalwa Works, Thane, India

Reporting To: Plant Manager, Kalwa Works

Functional Area: Manufacturing & Factory Operations

Scope & Impact:

The position is accountable for ensuring high availability and reliability of manufacturing assets, utilities, and infrastructure supporting the complete Kalwa manufacturing ecosystem, thereby enabling achievement of safety, quality, cost, delivery, and sustainability objectives. The role directly influences plant competitiveness through engineering excellence, technology upgrades, operational reliability, and digital transformation.

Mission / Purpose of the Position:

Lead the Plant Engineering function at Kalwa Works and ensure safe, reliable, sustainable, and cost-effective operation of manufacturing assets, facilities, utilities, infrastructure, automation systems, and special purpose machines.

Drive world-class maintenance practices, asset reliability, energy efficiency, digitalization, and continuous improvement initiatives to support operational excellence, business growth, and factory competitiveness while ensuring full compliance with Siemens EHS and statutory requirements.

The role owns the performance of plant infrastructure, manufacturing equipment, automation systems, and capital engineering projects critical to Kalwa's manufacturing operations.

Areas of Responsibility:

• Plant Reliability & Asset Management
• Define and execute the maintenance strategy for all manufacturing assets.
• Ensure optimum availability, reliability, and performance of production equipment.
• Implement preventive, predictive, and condition-based maintenance programs.
• Drive TPM and reliability engineering practices.
• Lead breakdown analysis and root cause elimination initiatives.
• Utilities & Infrastructure Management
• Ensure uninterrupted operation of plant utilities and infrastructure.
• Manage electrical distribution systems, compressed air systems, HVAC, water systems, fire protection systems, and buildings.
• Safeguard business continuity through robust utility and infrastructure management.
• Manufacturing Technology Support
• Support operation and maintenance of:
• Stamping presses
• Injection moulding machines
• Assembly systems
• Testing equipment
• Automation systems
• Special Purpose Machines (SPMs)
• Support introduction of new products and manufacturing technologies.
• Capital Investment & Engineering Projects
• Prepare and execute capital expenditure plans.
• Lead modernization, retrofit, expansion, and automation projects.
• Ensure projects are delivered within approved budget, quality, and schedule targets.
• Coordinate with internal and external stakeholders during project execution.
• Safety, Health & Environment
• Promote a zero-harm culture across all engineering activities.
• Ensure compliance with Siemens EHS requirements and statutory regulations.
• Conduct risk assessments and drive implementation of corrective actions.
• Support environmental and sustainability initiatives.
• Energy & Sustainability
• Drive energy efficiency and resource optimization initiatives.
• Support factory decarbonization objectives.
• Lead projects related to energy conservation, renewable energy utilization, waste reduction, and circularity.
• Cost & Budget Management
• Prepare and manage the annual maintenance and engineering budget.
• Optimize lifecycle costs of assets.
• Improve maintenance productivity and cost effectiveness.
• Manage contracts, service agreements, and engineering procurement activities.
• Digitalization & Continuous Improvement
• Drive digital maintenance and Industry 4.0 initiatives.
• Improve asset monitoring through condition monitoring and data analytics.
• Implement CMMS/EAM best practices.
• Support factory digitalization roadmap.
• People Leadership
• Lead and develop the Plant Engineering & Maintenance organization.
• Build technical competencies and succession pipelines.
• Foster a culture of accountability, innovation, collaboration, and continuous improvement.
• Ensure effective resource planning and capability development.
  
  

Key Performance Indicators

• Equipment Availability
• OEE Improvement
• Breakdown Hours
• MTBF / MTTR
• Maintenance Cost Performance
• Energy Consumption Reduction
• Utility Availability
• Capex Execution Performance
• Safety Performance
• Regulatory Compliance Status
• TPM Maturity
• Digitalization & Improvement Project Realization
  
  

Leadership Expectations

• Demonstrate Siemens leadership behaviors and values.
• Act as technical authority for plant engineering matters.
• Drive operational excellence and continuous improvement culture.
• Build strong cross-functional collaboration.
• Develop a high-performing engineering organization.
• Champion safety, sustainability, and digital transformation.
  
  

Qualifications

Education:

• Bachelor's Degree in Mechanical, Electrical, Electronics, Mechatronics, or equivalent Engineering discipline.
• Postgraduate qualification in Engineering, Operations, or Management preferred.
  
  

Experience

• 15+ years of experience in manufacturing operations, maintenance, or plant engineering.
• Proven experience managing multidisciplinary engineering teams.
• Experience in automation-intensive manufacturing environments.
• Hands-on experience in project management, facility management, and asset reliability.
  
  

Technical Competencies

• Maintenance Management
• TPM / Lean Manufacturing
• Reliability Engineering
• Industrial Automation
• Utilities Management
• Capex Project Management
• Industry 4.0 Technologies
• Energy Management
• Root Cause Analysis
• Continuous Improvement
  
  

Behavioral Competencies

• Strategic Orientation
• Customer Focus
• Collaboration
• Results Orientation
• Change Management
• People Development
• Stakeholder Management