Manager - Mechanical Maintenance

Location

Nagpur | India

Job description

• Adherence to maintenance schedule and maintenance budget
• Reduction in down time (Hours and Numbers)
• Reduction in cost of maintenance (Stores, spares and repair maintenance cost)
• No. of machine under Autonomous Maintenance
• Improvement in Plant reliability index
• % Reduction in accidents and unsafe conditions
• 5 Score improvement
• No. of Improvement initiatives (SPARSH Machine, Kaizan, Hira etc.)
• Training man days with focus on capability building

KEY ACTIVITIES RESPONSIBILITIES

Planning and Scheduling

• Plan for efficient maintenance and working of all machines and equipment s in the department
• Plan Mechanical maintenance schedule (Preventive and Predictive) in consultation with Maintenance head
• Prepare the plan for spares and consumables required for Mechanical maintenance
• Plan annual maintenance schedule in line with the annual plant shutdown plan

Operational

• Ensure proper and timely completion of all assigned mechanical maintenance jobs
• Be responsible for the execution and the quality of maintenance work to be carried out on all machines and equipment according to planned work orders
• Analyse equipment breakdowns, conduct root cause analysis and implement breakdown measures with subordinates
• Ensure proper day-to-day scheduling of work and necessary resources, assign work to the team and review their work
• Implement different maintenance procedures in order to have smooth running of the machines
• Ensure routine preventive maintenance is done and ensure production operators are familiar with required maintenance technique
• Regularly conduct training sessions for the shop floor operators and supervisors on correct methods of operations and usage of machine and equipment s
• Ensure timely completion of all mechanical maintenance jobs by the team. Ensure that vendor support is available for various equipment s
• Regularly inspect and oversee conditions of all machines and equipment s and highlight to seniors in case of any concerns.
• Effective liaison with other departments such as Production, Planning, Quality to plan and schedule work
• Monitor data on existing equipment s and machines condition, performance, machine life, and probable risks/ unique conditions. Accordingly, plan for new machine / equipment installation and commissioning, and other capital expansions in consultation with Senior Management
• Provide detailed inputs for identification of new machines when required
• Ensure AMCs are filed and in place for new machines installed
• Ensure monitoring of new equipment s post commissioning to ensure optimum performance
• Ensure team is trained on all maintenance procedure for the new machine installed to ensure best performance
• Coordinate with Original Equipment Manufacturers for training on specific technology, vibration analysis, etc. if required

Safety Compliance

• Ensure safety measures are necessarily followed by the team and take initiative to enhance acceptance of safety
• Report and ensure that a detailed RCAs in case of accidents
• Ensure all team members are adequately trained with respect to EHS
• Ensure compliance to the norms under ISO, OHSAS and any other standards as applicable from time to time
• Ensure all required documentation and certifications are in order in compliance with various norms
• Participate in internal and external audits and provide the required support

Cost Management

• Maintain and control maintenance cost within budget
• Reduce maintenance costs by initiating cost saving measures and through innovative ideas

Spares Management

• Responsible to raise PRs for spare parts and consumables required for Mechanical Maintenance in a timely manner
• Interact with the vendors and Stores team for obtaining spares and consumables as per requirement
• Provide all necessary specifications and support to the stores team to assist in selection of the most beneficial vendor / supplier
• Responsible for all spares and consumables issued from stores for Mechanical maintenance to ensure zero loss or damage and optimum utilization
• Review periodically inventory of spare parts, and supplies, anticipate needed equipment, parts, and supplies

Documentation, MIS, Review Analysis

• Maintain and review records of all maintenance work carried out in log books and SAP
• Maintain and update operating training manuals
• Ensure SAP is updated regularly and accurately by the team
• Review inventory sheet of spare parts and consumables and prepare stores and spares consumption an alysis
• Review record of spares and consumables used in maintenance activities
• Prepare Scrap analysis reports and reduction suggestions in case scrap generated as a result of mechanical failures
• Prepare and Review PM Effectiveness reports and scorecard

Team Relationship Management

• Guide and manage the maintenance team to ensure the department s objectives are met
• Ensure maintenance team is adequately trained and proactively work with HR at capability enhancement of team
• Conduct effective performance appraisals for the team and provide regular feedback
• Motivate, counsel and coach employees to ensure a conducive working environment

Improvement Projects

• Provide inputs and encourage team to work on improvement projects like Kaizen, QIP, 5S, Bol Bindaas, SPARSH, HIRA etc

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