Maintenance Manager

Job Purpose

To plan, lead, and control all maintenance activities across manufacturing shops to ensure maximum equipment availability, safe operations, cost optimization, and continuous improvement of machinery, utilities, and facilities.

Key Responsibilities

Maintenance Management

• Plan and execute preventive, predictive, and breakdown maintenance for:

– CNC machines

– Paint shop (pretreatment, booths, ovens, conveyors)

– Welding (MIG, TIG & Spot) and Welding robots

– Press shop (Mechanical and Hydraulic presses) & Hot Forging

– Laser cutting machines

– Injection moulding machines

– Fabrication and Assembly shops

– Forklifts and material handling equipment

• Ensure high equipment uptime and reliability.
• Develop maintenance SOPs, schedules, and checklists.

Maintenance Management – Utilities & Infrastructure

• Manage maintenance of plant utility systems, including:

– Air compressors and compressed air networks

– Power distribution systems (HT/LT panels, transformers, DG sets)

– Firefighting and safety systems

• Ensure uninterrupted availability of utilities to all production.
• Drive energy efficiency and utility optimization initiatives.

Team Leadership

• Lead and manage maintenance engineers, technicians, and electricians.
• Plan manpower deployment across shifts and critical areas.
• Conduct training on equipment, safety, and best maintenance practices.

Breakdown Handling & RCA

• Attend and resolve major breakdowns promptly.
• Perform root cause analysis (RCA) and implement corrective actions.
• Reduce recurring failures and unplanned downtime.

Automation & Controls

• Manage PLCs, HMIs, servo drives, robots, sensors, and control panels.
• Coordinate with OEMs and automation vendors for troubleshooting and upgrades.
• Support commissioning and integration of new machines and automation systems.

Spares & Cost Control

• Identify and manage critical spares inventory.
• Control maintenance costs and reduce emergency purchases.
• Prepare and monitor the maintenance budget.

Safety, TPM & Compliance

• Ensure compliance with safety standards and statutory requirements.
• Implement TPM, 5S, Kaizen, and continuous improvement initiatives.
• Implement CBAM (Carbon Boarder Adjustment Mechanism).

Projects & Continuous Improvement

• Support installation, commissioning, and stabilization of new equipment.
• Drive energy-saving, reliability, and productivity improvement projects.
• Track maintenance KPIs and improve performance.

Key Performance Indicators (KPIs)

• Equipment uptime and MTBF
• Breakdown frequency and downtime
• Preventive maintenance compliance
• Maintenance cost versus budget
• Safety performance (zero accidents)
• Spares availability and inventory control

Qualifications & Experience

• Bachelor’s Degree / Diploma in Mechanical, Electrical, Mechatronics, or related field.
• 10–15 years of maintenance experience in manufacturing.
• Strong exposure to CNC, robotics, press shop, Paint Shop, laser cutting, injection moulding, and automated assembly lines.
• Experience with TPM, and improvement tools preferred.