Maintenance Head

Job Title: Head of Maintenance / Maintenance Manager / Plant Maintenance Head / Senior Manager - Maintenance Department: Maintenance / Operations / Engineering Reports To: Plant Head / Factory Manager / Vice President - Operations Location: Ichalkaranji, Maharashtra, India (This is a senior plant-based role requiring significant on-site presence and strategic oversight). Job Summary: We are seeking an experienced, strategic, and results-oriented Head of Maintenance to lead our maintenance department in Ichalkaranji. The Maintenance Head will be responsible for developing and implementing a robust maintenance strategy to ensure the continuous, reliable, and safe operation of all plant machinery, equipment, and facilities. This includes optimizing maintenance processes, driving efficiency, managing budgets, leading a team of maintenance professionals, and fostering a culture of proactive maintenance and continuous improvement. Key Responsibilities: Strategic Planning & Leadership: Develop and implement the overall maintenance strategy and long-term plans aligned with the company's operational goals and production targets. Lead, mentor, and manage a team of maintenance engineers, supervisors, technicians, and fitters, fostering a high-performance, safety-conscious, and continuous learning environment. Define departmental goals, objectives, and KPIs (Key Performance Indicators) and regularly monitor performance to ensure targets are met. Drive the shift from reactive to proactive (preventive and predictive) maintenance practices to maximize asset uptime and reduce costs. Operational Excellence & Process Optimization: Oversee all aspects of maintenance operations, including preventive maintenance (PM), predictive maintenance (PdM), breakdown maintenance (BDM), and corrective maintenance. Implement and optimize maintenance procedures and Standard Operating Procedures (SOPs) for all critical equipment. Utilize and maximize the functionality of Computerized Maintenance Management Systems (CMMS) or ERP modules (e.g., SAP PM) for work order management, asset tracking, scheduling, and reporting. Conduct Root Cause Analysis (RCA) for recurring failures and implement effective long-term solutions. Lead continuous improvement initiatives (e.g., Lean Manufacturing, Total Productive Maintenance (TPM), Six Sigma) within the maintenance function to enhance efficiency and quality. Budget & Resource Management: Develop and manage the annual maintenance budget, controlling expenses related to labor, spare parts, consumables, and external services. Oversee spare parts inventory management, optimizing stock levels to ensure availability of critical components while minimizing carrying costs. Manage relationships with vendors, contractors, and service providers, negotiating contracts and ensuring quality of service. Technical Expertise & Project Management: Provide expert technical guidance and support for complex troubleshooting and repair activities, particularly for textile machinery (e.g., looms, spinning, processing) or other manufacturing equipment relevant to the plant. Oversee installation, commissioning, and validation of new machinery and equipment. Manage maintenance-related projects, including upgrades, overhauls, and CAPEX initiatives, ensuring timely completion and budget adherence. Safety, Health & Environment (SHE) Compliance: Ensure strict compliance with all local and national health, safety, and environmental regulations (e.g., Factory Act, EHS norms) and company policies. Implement robust safety protocols (e.g., LOTO procedures, confined space entry, hot work permits) and conduct regular safety audits. Promote a strong safety culture among all maintenance personnel. Reporting & Communication: Prepare and present comprehensive maintenance reports to senior management, including key performance indicators (KPIs), budget utilization, downtime analysis, and improvement initiatives. Collaborate effectively with other departments such as Production, Quality, Engineering, and Supply Chain to ensure seamless operations and alignment of goals.