Description:
To ensure the reliability, efficiency, and safety of all UHT and Tetra Pak process plant equipment and facilities through effective planning and execution of preventive, predictive, and corrective maintenance activities. The role is responsible for minimizing downtime, optimizing breakdown management, and ensuring compliance with HSE and HACCP standards within the process and packaging operations.
Roles & Responsibilities:
- Identify, plan, and schedule preventive and corrective maintenance work orders for UHT and Tetra Pak equipment.
- Ensure all preventive, predictive, and planned maintenance activities are completed as per the maintenance plan and within agreed timeframes.
- Conduct periodic inspections of machinery and utilities to ensure optimal performance and minimum unplanned stoppages.
- Coordinate and lead maintenance activities during unplanned or emergency situations to ensure quick restoration of operations.
- Verify and validate maintenance work quality by following standard checklists and documentation.
- Monitor the performance of UHT sterilizers, homogenizers, aseptic tanks, CIP/SIP systems, and Tetra Pak filling and packaging lines.
- Analyze equipment breakdown data to identify recurring issues and implement corrective and preventive actions.
- Optimize machine efficiency, reliability, and energy utilization through continuous improvement initiatives.
- Maintain and improve key metrics such as MTBF (Mean Time Between Failures) and MTTR (Mean Time To Repair)
- Plan and maintain adequate inventory levels of spare parts, tools, and consumables for UHT and Tetra Pak systems.
- Monitor maintenance expenditure against the approved budget and report deviations.
- Ensure accurate recording of maintenance activities, spare usage, and downtime in the Computerized Maintenance Management System (CMMS).
- Ensure maintenance work adheres to Health, Safety, and Environment (HSE) policies and HACCP standards.
- Maintain food-grade hygiene during maintenance operations to prevent contamination risks.
- Support internal and external audits by maintaining accurate maintenance records and compliance documentation.
- Promote a strong safety culture among maintenance staff through regular briefings and compliance checks.
- Assign daily maintenance activities and manage shift schedules for technicians and operators.
- Provide technical guidance and support during critical maintenance interventions.
- Conduct training programs to enhance team skills in UHT, aseptic systems, and Tetra Pak machinery.
- Foster teamwork and ensure adherence to maintenance SOPs and company policies.
KPIs
Uptime and equipment reliability (%)
Preventive maintenance schedule adherence (%)
Breakdown frequency and response time
MTBF and MTTR improvement
Maintenance cost vs. budget variance
HSE and HACCP compliance rate
Spare parts inventory accuracy
Work experience requirement
- 4–8 years of hands-on maintenance experience in a UHT process and Tetra Pak packaging environment (preferably Cream, dairy or food processing industry).
Qualification
- B. Tech (Mechanical)/Diploma Mechanical / ITI Fitter
Technical Skills:
- In-depth knowledge of UHT systems, homogenizers, aseptic process equipment, and CIP/SIP systems.
- Proficiency in troubleshooting Tetra Pak filling and packaging machines.
- Familiarity with PLCs, automation, instrumentation, and drives.
- Experience using CMMS or similar maintenance management tools.
- Sound understanding of HACCP, HSE, GMP, and food safety standards.
Competencies:
- Strong problem-solving and analytical abilities.
- Excellent planning and organizational skills.
- Effective leadership and team management.
- Strong communication and coordination abilities.
- Detail-oriented, with a commitment to safety and quality.
- Continuous improvement mindset.
