Job Description (JD)
Position Title: Head – Plant Maintenance
Location: Nagpur, Maharashtra
Industry: Solar PV Module Manufacturing
Plant Capacity: 7 GW (Large Integrated Manufacturing Unit)
Educational Qualification
- B.Tech / BE in Mechanical / Electrical / Electronics Engineering (mandatory)
- Postgraduate qualification in Engineering or Management will be an added advantage
Experience
- Minimum 18 years of total experience in plant maintenance
- At least 8–10 years in a leadership role handling maintenance of large manufacturing plants (preferably solar, semiconductor, electronics, automotive, or process industry)
- Experience in high-capacity, automated production lines is highly preferred
Role Purpose
The Head – Plant Maintenance is responsible for ensuring maximum equipment availability, reliability, and safety of the 7 GW solar module manufacturing facility. The role involves strategic planning, execution, and continuous improvement of mechanical, electrical, utility, and automation maintenance systems to support uninterrupted production and world-class operational excellence.
Key Responsibilities
1. Maintenance Strategy & Leadership
- Develop and implement short-term and long-term maintenance strategies aligned with plant objectives
- Lead, mentor, and manage a large multi-disciplinary maintenance team (Mechanical, Electrical, Utilities, Automation, Instrumentation)
- Establish a robust preventive, predictive, and condition-based maintenance system
- Drive a culture of safety, ownership, and continuous improvement across the maintenance function
2. Plant & Equipment Maintenance
- Ensure high uptime and reliability of:
- Solar module production lines (cell stringers, laminators, tabbers, testers, framing, etc.)
- Utilities: HVAC, compressed air, chillers, boilers, cooling towers, RO/DM water systems, power distribution
- Electrical systems: HT/LT panels, substations, DG sets, UPS, transformers
- Automation & control systems (PLCs, SCADA, robotics, vision systems)
- Lead breakdown analysis (RCA) and implement permanent corrective actions
- Manage spares planning, inventory optimization, and critical spares strategy
3. Project & Expansion Support
- Support new line installations, plant expansions, and capacity ramp-ups
- Review equipment layouts, utility sizing, maintenance accessibility, and safety during project phase
- Coordinate with OEMs, EPC contractors, and internal project teams for smooth commissioning and handover
4. Reliability & Continuous Improvement
- Implement TPM / RCM / Lean Maintenance practices
- Track and improve KPIs such as MTBF, MTTR, OEE, downtime, and maintenance cost per MW
- Drive energy efficiency and cost-reduction initiatives
- Leverage digital maintenance systems (CMMS, predictive analytics, IoT tools)
5. Safety, Compliance & Audits
- Ensure 100% compliance with statutory, legal, and safety requirements
- Lead HSE initiatives, safety audits, risk assessments, and emergency preparedness
- Ensure compliance with ISO 9001, ISO 14001, ISO 45001 and other relevant standards
- Coordinate internal and external audits related to maintenance and utilities
6. Budgeting & Cost Control
- Prepare and manage annual maintenance budgets and CAPEX plans
- Control maintenance costs without compromising reliability and safety
- Negotiate and manage AMC, service contracts, and vendor performance
Key Skills & Competencies
- Strong expertise in mechanical, electrical, utilities, and automation maintenance
- Proven leadership and people management capabilities
- Excellent problem-solving, analytical, and decision-making skills
- Hands-on experience with highly automated manufacturing environments
- Knowledge of solar module manufacturing equipment is a strong advantage
- Strong communication and stakeholder management skills
- Proficient in CMMS, SAP PM or similar maintenance systems
Key Performance Indicators (KPIs)
- Plant uptime and equipment availability
- Reduction in unplanned downtime
- Maintenance cost optimization
- Safety performance (zero LTI)
- Energy efficiency improvements
- Audit and compliance scores
