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What are the Key Deliverables in this role?
Financial Outcomes
- Reduce maintenance expenditure, Save on power and fuel cost, Cost Saving through Kaizen and Cost Saving Projects
- Achieve annual maintenance cost reduction through effective preventive maintenance, root cause analysis, and optimization of maintenance activities.
- Reduce machine breakdown losses and maintenance expenditure by improving equipment reliability and increasing Mean Time Between Failures (MTBF).
- Drive energy cost savings by optimizing consumption of electricity, diesel, PNG, compressed air, steam, and water utilities.
- Identify, implement, and sustain cost-saving projects through Kaizen, TPM, process improvement, and automation initiatives.
- Support annual budgeting and ensure maintenance expenses remain within approved budgets through effective cost control measures.
- Generate measurable savings through value engineering, vendor development, and procurement optimization initiatives.
- Minimize production losses due to equipment failures by maintaining high machine availability and Overall Equipment Effectiveness (OEE).
- Improve maintenance productivity through manpower optimization, resource planning, and contractor cost control.
- Achieve targeted cost reductions in utilities and operational expenditure through continuous improvement and energy conservation initiatives.
- Deliver year-on-year financial benefits through TPM, reliability improvement projects, breakdown reduction, and process automation programs.
Customer Service
- Ensure uninterrupted production support and high machine availability.
Internal Processes: PM compliance, downtime reduction, critical spares management, statutory compliance and timely MIS reporting
- Ensure uninterrupted production by maintaining high machine availability and minimizing unplanned breakdowns.
- Collaborate closely with Production, Quality, Planning, Warehouse, and EHS teams to address operational issues and ensure smooth plant operations.
- Maintain high equipment reliability through effective preventive, predictive, and condition-based maintenance practices, resulting in improved Overall Equipment Effectiveness (OEE).
- Respond promptly to production emergencies and critical equipment failures to minimize downtime and prevent disruptions and service levels.
- Ensure availability and reliability of critical utilities including power distribution systems, DG sets, compressors, boilers, HVAC systems, water systems, and other plant infrastructure.
- Drive continuous improvement initiatives to enhance equipment performance, process efficiency, product quality, and operational responsiveness.
- Support new capacity expansion projects, and process modifications by ensuring timely engineering and maintenance support.
- Develop and maintain strong working relationships with internal stakeholders and external service providers to ensure effective resolution of technical issues and service requirements.
- Ensure timely execution of preventive maintenance schedules without impacting production requirements.
- Maintain adequate availability of critical spare parts and maintenance resources to ensure rapid restoration of equipment during breakdown situations.
- Monitor and improve key performance indicators such as Machine Availability, OEE, Breakdown Hours, MTBF, MTTR, Preventive Maintenance Compliance, and Utility Reliability.
- Ensure adherence to statutory, safety, quality, food safety, and environmental requirements while delivering maintenance services.
Internal Processes
- Adherence to internal and external audit compliance
- Ensure proper maintenance documentation, equipment history records, maintenance logs, calibration records, utility consumption records, and statutory compliance documents.
- Lead Annual Maintenance Contracts (AMC), service contracts, vendor evaluation, contractor management, and technical audits to ensure quality service delivery and cost optimization.
- Ensure compliance with all statutory requirements relating to electrical systems, boilers, pressure vessels, fire safety systems, lifts, HVAC systems, DG sets, and other regulated equipment.
- Maintain adherence to Quality, Food Safety, GMP, EHS, ISO 9001, ISO 14001, ISO 45001, FSSAI, and other applicable regulatory requirements.
- Coordinate and support internal audits, external audits, customer audits, certification audits, and regulatory inspections while ensuring timely closure of observations and non-conformities.
- Drive digitalization and SAP-based maintenance management by ensuring accurate maintenance planning, work order management, spare consumption tracking, and reporting.
- Ensure effective contractor safety management, permit-to-work implementation, risk assessment, and safe maintenance practices during all maintenance and project activities.
- Prepare and submit timely MIS reports covering maintenance performance, project status, utility consumption, downtime analysis, cost control measures, and improvement initiatives.
- Develop technical competency within the maintenance team through structured training programs, skill development initiatives, succession planning, and knowledge-sharing activities.
- Establish a culture of reliability, safety, compliance, and continuous improvement by driving accountability, process discipline, and performance excellence across maintenance functions.
Innovation and Learning
- TPM implementation, automation projects, OEE improvement, Kaizen and capability development.
- Lead the implementation and sustainability of Total Productive Maintenance (TPM) initiatives by driving focused improvement projects, autonomous maintenance, planned maintenance, and reliability enhancement programs across all plant equipment and utilities.
- Foster a culture of continuous improvement by identifying opportunities for Kaizen, process optimization, waste elimination, productivity improvement, and operational excellence throughout the manufacturing facility.
- Identify and execute cost-saving projects through energy conservation, utility optimization, process automation, equipment modification, and engineering improvements while delivering measurable business benefits.
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