Head of Maintenance

Company Description

Shanku's Bio-Sciences is a chemistry contract research organization engaged in the pharma and agrochemical sector. The company primarily manufactures Pharma Intermediates, APIs, and specialty chemicals. They also produce animal feed products. Shanku's Bio-Sciences is dedicated to delivering high-quality chemical solutions for various industries.

Role Description

KRA for Maintenance Head

1. Equipment Maintenance Management

Objective

Key Responsibilities

• Develop, implement, and manage a comprehensive Preventive Maintenance (PM) program to minimize unplanned downtime.
• Ensure corrective maintenance is performed in a timely and cost-effective manner.
• Oversee the identification and troubleshooting of equipment failures or malfunctions, coordinating repairs and adjustments.
• Maintain detailed records of all maintenance activities, including service logs, maintenance schedules, and reports on repairs or breakdowns.
• Work with vendors for the repair and servicing of specialized equipment.

Key Performance Indicators (KPIs)

• Equipment downtime (scheduled vs. unscheduled)
• Mean time between failures (MTBF)
• Mean time to repair (MTTR)
• Maintenance cost per unit of production

2. Team Management and Development

Objective

Key Responsibilities

• Supervise and lead a team of maintenance technicians, ensuring they follow SOPs and safety protocols.
• Ensure the team is properly trained and skilled in the latest maintenance techniques, technologies, and safety procedures.
• Conduct performance reviews and provide feedback to maintain high performance standards.
• Foster a positive work environment and encourage teamwork and cooperation across the plant.

Key Performance Indicators (KPIs)

• Employee training completion rates and skill development
• Team productivity and performance ratings
• Employee retention and turnover rate

3. Safety and Compliance

Objective

Key Responsibilities

• Ensure all maintenance activities comply with local, state, and national safety regulations, environmental guidelines, and industry standards.
• Lead and participate in safety audits and inspections within the maintenance department.
• Ensure proper use of personal protective equipment (PPE) and ensure the team adheres to safe working practices.
• Investigate and report any safety incidents, accidents, or near misses in the maintenance department and implement corrective actions.

Key Performance Indicators (KPIs)

• Number of safety incidents or accidents
• Compliance audit success rate
• Safety training completion rates

4. Spare Parts and Inventory Management

Objective

Key Responsibilities

• Manage and optimize the inventory of spare parts and maintenance supplies.
• Ensure critical parts are available on-site or have a well-maintained supplier network to ensure quick procurement.
• Regularly audit the spare parts inventory and ensure proper storage and handling of parts to prevent damage or degradation.

Key Performance Indicators (KPIs)

• Stockouts and critical part availability
• Inventory turnover rate
• Spare parts procurement lead time

5. Budget and Cost Control

Objective

Key Responsibilities

• Develop and manage the annual maintenance budget, including labor, spare parts, equipment repairs, and external services.
• Track maintenance costs against budget and implement cost-control measures where necessary.
• Identify areas for cost savings without compromising equipment reliability or safety.
• Optimize the use of resources and materials to improve cost efficiency in maintenance operations.

Key Performance Indicators (KPIs)

• Maintenance cost variance (Actual vs. Budgeted)
• Cost per unit of maintenance work
• Number of cost-saving initiatives implemented

6. Continuous Improvement and Innovation

Objective

Key Responsibilities

• Implement lean maintenance practices and other continuous improvement methodologies to optimize maintenance operations.
• Stay up to date with the latest maintenance technologies and industry trends (e.g., condition-based monitoring, predictive maintenance).
• Conduct root cause analysis of recurrent equipment failures and implement corrective measures to eliminate the root cause.
• Foster a culture of innovation and problem-solving within the maintenance team.

Key Performance Indicators (KPIs)

• Number of continuous improvement initiatives successfully implemented
• Reduction in repetitive equipment failures
• Adoption rate of new maintenance technologies or methodologies

7. Collaboration with Other Departments

Objective

Key Responsibilities

• Work closely with production and operations teams to minimize downtime during scheduled maintenance or repairs.
• Coordinate with the engineering team on equipment upgrades or new installations, ensuring timely and cost-effective execution.
• Participate in production planning meetings to align maintenance schedules with production goals and priorities.
• Collaborate with the quality team to ensure maintenance activities support high-quality production standards.

Key Performance Indicators (KPIs)

• Reduced unplanned downtime during production hours
• Maintenance schedule adherence and coordination effectiveness
• Timely completion of cross-departmental projects

General Responsibilities

• Develop and implement maintenance policies, procedures, and safety guidelines.
• Prepare and present regular maintenance performance reports to senior management.
• Ensure a proactive approach to identify potential areas for improvement in the plant’s operations and maintenance processes.
• Handle emergency repairs, ensuring minimum disruption to plant operations.