Responsible for preventive and reactive maintenance activities of plant equipment and systems as per maintenance plan to ensure maximum productivity and efficiency while maintaining accuracy, quality of production and cost controls
1.Maintenance planning and monitoring
Conduct planning for regular, preventive and reactive maintenance activities for utility machines, plant vehicles, tool maintenance, plant facilities and buildings as per the BU maintenance teamPerform manpower planning for the maintenance function at the plant level and allocate work within the team as per employee specialization and experienceFacilitate maintenance for machine software and programs with ensured backlog of 3 yearsTrack and analyze key maintenance parameters such as mean time failure, depreciation cost, asset utilization, maintenance cost, compliance to machine operating parameters, etc. and feed it as input to BU Maintenance team for further planningOversee new machine installation inclusive of commissioning, installation and handover to shop floor workers2.Cost reduction
Monitor expenditure on maintenance activities across the plant ensuring adherence to allocated budgetIdentify and execute cost saving measures and projects in order to reduce maintenance cost and reduce capex, inclusive of preventive maintenance for old-age machines, planning and development of machines in house, standardization of machines, maintaining low spare part inventory and managing procurement of non-BOM itemsConduct root cause analysis and contingency planning to prevent repeated breakdown of parts, machines3.Energy management
Lead the utility team to carefully monitor energy consumption and track trends on a regular basisMonitor the energy load to ensure it stays within the sanctions provided by the electricity board. Procure additional sanctions for increased electricity loads4.Audits, Controls and Compliance
Plan and manage plant audits in addition to everyday QA checks, including corporate audit for asset verification as per age and cost of machines, Poka Yoke, TPM, ISO/TS and OSHA auditsFacilitate machine and equipment audits required by customers and submit reports to concerned stakeholdersManage compliances and utilization of MEP technologies, including MIDC for water, MACB for electricity, effluent treatment plant maintenance etc.Track and ensure adherence to maintenance controls against sales and ensure standardization of inventory controls5.New Product Development and Digital Initiatives
Participate in cross-functional team responsible for design and approval process of new product development and line shiftsAssess and plan for integration of new product development through in-house development of new machines, existing machine upgradation or modification as per customer requirements for new parts, productsSupport Manufacturing Excellence (ME) teams through IoT to identify minor stoppages and suggest enhancements and improvements of new machines6.Team development
Carry out performance appraisal of direct reports and identify team members training needs and areas of improvementEnsure maintenance staff is adequately trained, equipped and motivated so that the maintenance work can be completed in a safe, timely and cost-effective mannerConduct training sessions for shop floor operators and supervisors on correct methods of operations and usage of machine and equipment
