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KEY ACTIVITIES & RESPONSIBILITIES
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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
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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
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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
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Cost Management
- Maintain and control maintenance cost within budget
- Reduce maintenance costs by initiating cost saving measures and through innovative ideas
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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
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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 analysis
- 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
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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
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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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