Maintenance Head

Job Title:

Plant Maintenance Head Aluminium Extrusion

Department: Engineering / Maintenance

Reports To: Plant Head & President

Location: Kharagpur

Grade / Level: Senior Management (Sr Manager – as applicable)

Job Purpose:

maximum equipment availability, operational reliability, safety compliance, energy efficiency, and cost optimization

Key Responsibilities:

1. Plant & Equipment Maintenance

• Ensure

  24/7 operational availability

  of extrusion presses (e.g., 660T–3600T or higher), billet heaters, hot saws, pullers, run-out tables, stretchers, aging ovens, and packing systems.
• Plan and execute

  preventive, predictive, and breakdown maintenance

  for all mechanical, electrical, hydraulic, pneumatic, and automation systems.
• Develop and implement

  annual maintenance plans

  , shutdown schedules, and overhauling programs.
• Minimize

  unplanned downtime

  , improve MTBF, and reduce MTTR.

2. Extrusion-Specific Equipment Expertise

• Maintenance oversight of:
• Extrusion presses and hydraulics
• Container, stem, dummy block systems
• Billet heating and temperature control systems
• Quenching systems (air/water)
• Pullers, stretchers, and run-out systems
• Aging furnaces (batch/continuous)
• Die ovens, die handling, and auxiliary equipment
• Provide technical support for

  die-related issues

  impacting extrusion quality and productivity.

3. Utilities & Infrastructure Management

• Manage utilities including:
• Power distribution systems, transformers, DG sets
• Compressed air systems
• Cooling towers and water treatment plants
• Chillers and HVAC (if applicable)
• Ensure optimal energy consumption and support

  energy conservation initiatives

  .

4. Automation & Electrical Systems

• Oversee maintenance of:
• PLC, HMI, SCADA, drives (ABB/Siemens/Allen Bradley, etc.)
• Sensors, instrumentation, and control panels
• Lead troubleshooting of automation failures and continuous system upgrades.

5. Spare Parts & Inventory Management

• Define

  critical spares list

  for extrusion presses and utilities.
• Control spare parts inventory to ensure availability while optimizing working capital.
• Develop vendor base for OEM spares and local alternatives.

6. Safety, Compliance & Statutory Requirements

• Ensure compliance with:
• Factory Act & statutory inspections
• Electrical safety, pressure vessel norms
• ISO 9001, ISO 14001, ISO 45001 standards
• Conduct regular safety audits, risk assessments, and toolbox talks.
• Lead accident investigation and preventive action implementation.

7. Cost Control & Budgeting

• Prepare and control

  maintenance budgets (OPEX & CAPEX)

  .
• Identify cost reduction opportunities through:
• Reliability improvement
• Vendor optimization
• In-house repairs and refurbishment
• Evaluate and recommend CAPEX for equipment upgrades or replacements.

8. Team Leadership & Development

• Lead a multidisciplinary team of:
• Mechanical, Electrical, Automation engineers
• Technicians and fitters
• Develop skill matrices, training plans, and succession planning.
• Foster a culture of

  ownership, discipline, and continuous improvement

  .

9. Continuous Improvement & TPM

• Implement

  TPM, 5S, Kaizen, and Lean Maintenance

  practices.
• Analyze breakdown trends and lead root cause analysis (RCA).
• Improve OEE of extrusion presses and downstream processes.

10. Coordination with Other Departments

• Work closely with:
• Production for planning and uptime
• Quality for defect reduction related to equipment
• Stores & Purchase for spares and services
• Projects team for new installations and expansions

Key Performance Indicators (KPIs):

• Equipment availability & uptime %
• Extrusion press OEE
• Breakdown frequency and duration
• Maintenance cost per MT of extrusion
• Energy consumption per MT
• Safety incidents (zero LTI target)
• Statutory compliance score

Educational Qualifications:

• B.E./B.Tech in Mechanical only

• Postgraduate qualifications or certifications in Maintenance

Experience:

• 15–25 years

  of experience in plant maintenance

• Minimum 8–10 years

  in a leadership role
• Mandatory experience in

  Aluminium Extrusion or Aluminium Processing Industry or Maintenance in Hydraulics Machineries

• Hands-on exposure to

  large extrusion presses and utilities

Technical Skills:

• Strong knowledge of:
• Hydraulics and high-pressure systems
• Electrical power systems and drives
• PLC-based automation
• Preventive & predictive maintenance tools
• Familiarity with CMMS / SAP PM modules

Behavioural Competencies:

• Strong leadership and decision-making skills
• Analytical and problem-solving mindset
• Ability to work under pressure in a 24/7 manufacturing environment
• Excellent communication and cross-functional coordination

Working Conditions:

• Plant-based role
• Requires availability during breakdowns and shutdowns

Role & responsibilities

Preferred candidate profile