Mechanical Manager

Job Description

Position: Manager Mechanical Work Location: Moxi (Savli) - Vadodara Experience: 13 to 15 Years of experience in maintenance of equipment in a polymer or petrochemical industry. Role & responsibilities: Responsible for maintenance of all mechanical equipment of the plant in order to keep the assets in healthy condition, improve plant reliability and availability. Implement best operation & maintenance practices, PM/PdM maintenance to reduce breakdown through SAP implementation and spares management. Analyse the upset/failure and take corrective & preventive action for future to avoid recurrence of the problem and resolve chronic issues. Ensure that all activities of Mechanical and associated contractors are done in accordance with SHE guidelines. Key member of site ISO implementation team. Environment/Context/Complexity of the job: Internal: Compliance to SHE guidelines. Compliance to quality standard ISO and Environment Management System Knowledge of techniques for efficient use of energy and plant operation. Compliance to Company guidelines. External: Liaison with Statutory Authorities and other outside agency for timely compliance to Boilers, Gas, Pressure vessels, lifting tools testing & inspection. Dealing with contractors for effective and safe work at site. Responsibilities/Accountabilities of the job: Describe the main results expected from the job. Key Result Areas: Incident free operations, Adherence to SHE guidelines, Compliance of local regulations. Major Activities: Participate in regular safety training at site: Safety rules and guidelines Operating procedures Incident sharing and learning Permit to work and Risk Assessment, etc. Active support to the safety culture at site and work safely for incident free operation. Understand and follow annual SHE improvement plan for the site. Work in line with SHE KPIs and Targets set by management from time to time. Contribute to Behavior Based Safety (BBS) program at site. Participate on training at site to take BBSO to next level of reporting. Support Site SHE committee to resolve safety issues and drive SHE performance. Be conscious that all incidents including Near Miss at site must be reported, investigated and action items must be tracked to closure. Active use of KMS for incident reporting and investigation, MOC, action item tracking Collaborate to track and close all SHE related action items from audit, plant walkthroughs. Support the Asset Manager, responsible for the overall integrity of the site. Contribute to Asset Care program Take responsibility for maintaining the asset and integrity of the protective system. Follow site procedures aligned. Accountable for Following and practicing 20 principles of Behavior Safety and Process Safety at site Following and practicing Life Saving Rules at site Safety of other Employees, Contractors, Visitors and partners at site Following Permit to Work as per the site procedure Following Management of Change (MOC) as per the site procedure. Responsible for Participating in HAZOPs at site as per procedure Tracking action items from HAZOP to closure. Work in compliance with all legal regulations. Adherence to site licenses and permits. Participate on the Sustainability program at site. Stop work whenever there is an unsafe condition and immediately inform the Shift Leader and/or Head of Department. Directly intervene with those in your working area not using PPE or not following Company standards and procedures. Maintain the respective workplace in order and clean, as per best practices of housekeeping. Outcome: Zero incident/accident in the plant with sustainability and safe operation. Key Result Areas: Maintenance of plant equipment Major Activities: Safe and trouble free maintenance of all equipment installed in the plant. Execute Preventive and predictive maintenance of all equipment as per the schedule and maintenance procedures Task lists in SAP. Monitor the pending PM/PdM and keep the track for early compliance. Ensure that Task list for PM/PdM/AMC are thoroughly prepared and followed strictly during maintenance. Monitoring the performance of plant equipment of production area such as Base rubber, Graft, coagulation, compounding plant, DM plant, Refrigeration plant, filtration plant, Steam Boilers, cooling tower, WWTP and implement measures for reliability improvement. Ensure availability of updated documentation such as P&IDs, operation & service manuals, GA drawings, Piping drawings, stress analysis, fabrication drawings and SOPs/SMPs etc. Ensure latest documentation/P&ID sets are available in designated areas and in good condition Ensure process safety inspection plan is prepared and executed in the plant as per the schedule. Ensure that all standby equipment are always available for operation. Repairs to be done immediately in case of any problem. Outcome: Effective maintenance system in place for smooth operation. Key Result Areas: Normal operation / Startup / Shutdown of equipment Major Activities: Follow all SHE guidelines and work procedures during daily operation, startups and shutdown of equipment in consultation with production department. Ensure safe practices are followed during startup and shut down of equipment according to OEM recommendation and production requirement. Ensure equipment are operated within norms and plan for corrective measures in case of deviations. For shutdown proper planning should be done in advance with Time chart for the stop/start activity, spares requirement, manpower planning and other resources required. Outcome: Perform safe and smooth operation of the plant / startup / shutdown Key Result Areas: Monitoring of equipment healthiness. Major Activities: Prepare preventive & predictive maintenance schedule and implement the same through SAP in Co-ordination with production department. Pending PM/PdM to be tracked and completed within tolerance time limit Record history for preventive maintenance and breakdown maintenance. Root cause analysis of equipment to reduce breakdowns and implement recommended actions. Prompt action for attending the breakdown to restore the production. Ensure Zero leakages of any Utilities / Lubricants / Pump seals with effective monitoring and fixing plan. Outcome: Reduction in downtime of equipment. Key Result Areas: Maintenance of Environmental Facilities Major Activities: Maintenance of Environment facilities at site such as Wastewater treatment plant etc. according to legal requirement. Prepare and implement preventive maintenance plan for these facilities. Ensure safe practices are followed during operation and maintenance. Outcome: Improve Reliability of environmental facility Key Result Areas: Energy & Quality management and statutory compliances. Major Activities: Prepare documentation and implement ISO 9001:2008 QMS & ISO 14001:2004 EMS systems. As a part of ISO 50000 leadership team, active participation and drive the energy management program at site. Corrective action to be taken on suggestion of internal or external auditor. As part of statutory requirement testing & Inspection of boiler, pressure vessel and lifting tools and tackles testing. Outcome: Comply Statutory requirement, Energy management and Quality & Environment Management system Key Result Areas: Preventive Maintenance and spares management through SAP Major Activities: Maintain spares for its requirement during preventive maintenance, breakdown and day to day routine maintenance work. To prepare PM plan in SAP and execute maintenance work through SAP-PM module. Prepare & updating plant Equipment list in SAP-PM with BOM of their spares. Updating maintenance Task list in SAP for PM of each equipment and AMC activities. Preparation, review & implementation of Predictive Maintenance (PdM) plan for the Mechanical/Utility equipment. Take corrective action for the abnormality shown in the vibration monitoring, Oil testing, thickness testing reports and arrange re-inspection for verification. Maintain minimum required inventory of critical spares in stores as per the defined list. Spares available in stores and in department should be checked and tested in advance and kept as ready to use to reduce equipment downtime for maintenance. Outcome: Maintenance through SAP and Reduction in down time with proper planning of spares