Maintenance Manager will be responsible for ensuring maximum availability, reliability, and efficiency of all plant machinery, utilities, and infrastructure in the water heater manufacturing facility. The role involves leading preventive and predictive maintenance activities, minimizing downtime, improving equipment performance, ensuring compliance with EHS standards, driving 5S implementation, and supporting continuous improvement initiatives and cost saving.
Responsibilities
- Plan, organize, and monitor preventive, predictive, and breakdown maintenance activities for manufacturing equipment and utilities.
- Ensure minimum machine downtime and uninterrupted production operations.
- Maintain and troubleshoot critical equipment
- Develop maintenance schedules, checklists, and SOPs for all machinery and equipment.
- Ensure calibration and maintenance of critical instruments and equipment.
- Conduct root cause analysis (RCA) for recurring equipment failures and implement CAPA.
- Drive TPM, Kaizen, Lean Manufacturing, and continuous improvement initiatives.
- Improve equipment reliability, MTBF, and reduce MTTR.
- Identify and implement energy-saving and cost-reduction initiatives.
- Lead and supervise maintenance engineers, technicians, electricians, and contract manpower.
- Allocate work responsibilities and monitor team productivity.
- Conduct technical and safety training programs for maintenance personnel.
- Build a culture of accountability, discipline, and operational excellence.
- Ensure strict compliance with EHS (Environment, Health & Safety) standards, statutory regulations, and company safety policies.
- Implement safe maintenance practices including Lockout/Tagout (LOTO), permit systems, and risk assessments.
- Ensure compliance with electrical safety, fire safety, hazardous material handling, and machine guarding requirements.
- Participate in safety audits, incident investigations, and corrective action implementation.
- Drive zero-accident culture and improve shopfloor safety awareness.
- Ensure all maintenance activities comply with ISO, safety, and environmental audit requirements.
- Drive implementation and sustenance of 5S practices across maintenance workshops, utility areas, stores, and shopfloor.
- Ensure workplace cleanliness, visual management, tool organization, and standardized maintenance practices.
- Conduct regular 5S audits and implement corrective actions.
- Promote discipline and continuous workplace improvement culture.
- Ensure smooth functioning of utilities
- Manage inventory of critical spare parts and consumables.
- Coordinate with vendors, OEMs, and AMC service providers.
- Evaluate vendor performance and ensure timely procurement support.
- Maintain maintenance records, machine history cards, downtime analysis, and statutory documentation.
- Prepare MIS reports related to maintenance KPIs, utility consumption, and maintenance budgets.
- Monitor maintenance expenses and ensure cost control within approved budgets.
Preferred candidate profile
- B tech -Mechanical/Electrical
- Minimum 12+ years in plant Maintenance in Water Heater manufacturing unit. Having good knowledge in maintaining machineries availability as per plan. Strong knowledge of mechanical, electrical, pneumatic, hydraulic, and utility systems.
- Minimum- 5-7 Years experience in Managerial Role, handling Maintenance team.
- Proficiency in SAP systems and MS Office.
- Knowledge of TPM, Lean Manufacturing, Kaizen, and continuous improvement methodologies.
- Strong knowledge of mechanical, electrical, pneumatic, hydraulic, and utility systems.
- Expertise in preventive and predictive maintenance practices
