Maintenance & Plant Head

I. Basic Mission

The Engineering & Maintenance Head will be responsible for ensuring uninterrupted operations of all production, packaging, utility, and energy systems in a fully automated bread, rusk, pao and bun manufacturing facility. Expertise in preventive and predictive maintenance, automation systems, and energy management (including solar power plant operations).

Will be responsible for overseeing the overall maintenance, engineering operations, and utility systems of a fully automated manufacturing unit. The role demands a hands-on leader with deep technical expertise in automated bakery production lines (preferably WP Haton or similar European make) and strong team management capabilities to ensure uninterrupted plant operations, maximum equipment uptime, and adherence to safety and quality standards.

II. Main responsibilities

Equipment Reliability and Uptime

Ensure high equipment availability across all automated lines mixing, moulding, proofing, baking, cooling, slicing, and packaging.

Ensure optimum performance and minimal downtime of automatic bread and buns lines, preferably WP Haton, Koenig, Mecatherm, or similar European systems. Analyze equipment performance data to identify chronic issues and implement permanent corrective actions.

Coordinate with OEMs and automation vendors for critical equipment maintenance and upgrades.

Oversee electrical, mechanical, pneumatic, and hydraulic systems across the plant and surrounding premises (earthing, plumbing, solar installations).

Preventive and Predictive Maintenance

Develop, implement, and monitor preventive maintenance (PM) schedules for all production and packaging machinery.

Use predictive maintenance tools (vibration analysis, thermography, condition monitoring) to preempt failures.

Maintain detailed maintenance records through Computerized Maintenance Management System (CMMS) provided by German technology partner. Track KPIs such as MTBF (Mean Time Between Failures) and MTTR (Mean Time to Repair).

Automation, Electrical & Instrumentation Systems

Oversee maintenance of PLC, SCADA, sensors, drives, and servo systems integrated into automated lines.

Troubleshoot automation and control issues promptly to avoid production disruptions. Maintain up-to-date documentation for electrical drawings, control panels, and instrumentation systems.

Ensure calibration of all measuring instruments (temperature, pressure, humidity, weight, etc.).

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Utility and Facility Management

Manage operation and maintenance of boilers, chillers, compressors, HVAC systems, water treatment, and DG sets.

Monitor energy, steam, and water usage to ensure optimal efficiency. Maintain statutory compliance for pressure vessels, electrical installations, and utility systems.

Breakdown Management and Root Cause Analysis

Lead the response team for unplanned breakdowns to ensure minimal downtime. Conduct detailed Root Cause Analysis (RCA) for repeated equipment failures and implement CAPA (Corrective and Preventive Actions).

Create knowledge documentation for recurring issues and preventive measures.

Solar Power Plant and Energy Management

Oversee the operation, maintenance, and performance monitoring of the solar power plant.

Ensure synchronization between solar generation, plant load, and grid supply. Track daily generation, inverter performance, and cleaning/maintenance of solar panels.

Work towards maximizing renewable energy utilization and reducing grid dependency.

Maintain records for energy audits and sustainability reporting.

Spare Parts, Inventory, and Vendor Management

Maintain optimal inventory of critical spares and consumables.

Develop vendor relationships for timely procurement and technical support. Implement cost control measures and track maintenance budgets.

Maintain AMC contracts and evaluate vendor performance periodically.

Safety, Compliance, and Audits

Ensure adherence to electrical safety, machine safety, and energy safety standards. Conduct regular safety audits and training for maintenance personnel. Maintain statutory compliance for all plant machinery and installations. Support EHS team in risk assessments, fire safety checks, and environmental controls.

Team Management and Skill Development

Provide the list of tasks and schedules for the plant's personnel during normal operating hours, scheduled outage and forced outage scenarios.

Induction and plant specific MEP training for all newly inducted team members. Lead, train, and motivate the maintenance and engineering team across mechanical, electrical, and instrumentation disciplines.

Develop cross-functional skills and promote a culture of continuous improvement. Ensure round-the-clock maintenance coverage through effective shift planning.

Continuous Improvement and Innovation

Drive Kaizen, TPM (Total Productive Maintenance), and energy efficiency initiatives. Recommend and implement technology upgrades to improve reliability and reduce maintenance costs.

Participate in capex planning for equipment modernization and automation improvements.

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III. Key Skills & Competencies

Technical Expertise & Troubleshooting

Team Leadership & Mentoring

Preventive & Predictive Maintenance

Equipment Efficiency Optimization

Process Automation & Continuous Improvement

Safety, Compliance & Quality Focus

IV. Qualifications & Experience

Bachelor's degree in mechanical / electrical / industrial engineering (Master's preferred).

Minimum 15 years of experience in engineering and maintenance functions within the bakery or food processing industry, specifically in automated bread and bun manufacturing plants.

Hands-on experience with WP Haton lines or equivalent international bakery automation systems is highly preferred.

Knowledge of PLCs, SCADA, and automation controls preferred.

Excellent communication, troubleshooting, and decision-making abilities. Very good documentation skills

V. Relationships

Hierarchic:

The Plant Maintenance Head will report to the Plant Head. Will lead a multi-disciplinary engineering team to maximize plant reliability, minimize downtime, and ensure compliance with safety and regulatory standards.

VI. Location

Lucknow India

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