Maintenance Manager

We are seeking a highly experienced and technically sound Maintenance Manager to lead the maintenance operations of our LABSA manufacturing facility in Surat GIDC. The ideal candidate will ensure maximum plant reliability, minimize downtime, and maintain strict adherence to industrial safety and environmental standards. You will be responsible for overseeing the mechanical, electrical, and instrumentation maintenance of sulfonation reactors, heat exchangers, pumps, and scrubbing systems handling hazardous and corrosive chemicals.

Key Responsibilities

1. Plant Reliability & Maintenance

• Strategy Execution: Develop and execute comprehensive Preventive, Predictive, and Breakdown maintenance schedules for the entire LABSA plant.
• Equipment Upkeep: Oversee the maintenance of critical chemical processing equipment, including sulfonation reactors, glass-lined vessels, heat exchangers, boiler systems, cooling towers, and acid storage tanks.
• Downtime Reduction: Analyze frequent breakdown patterns (Root Cause Analysis - RCA) and implement corrective actions to improve Mean Time Between Failures (MTBF) and reduce Mean Time To Repair (MTTR).
• Rotary & Static Equipment: Ensure the optimal performance of specialized rotary equipment (e.g., acid pumps, blowers, compressors) and static equipment handling Oleum, SO3, and Sulfuric Acid.

2. Shutdown & Project Management

• Turnaround Planning: Plan, budget, and execute annual plant shutdowns efficiently without extending the timeline.
• Modifications: Coordinate with the process engineering team for plant debottlenecking, expansion projects, and the installation of new equipment.

3. Safety, Health, & Environment (HSE) Compliance

• Hazardous Operations: Ensure all maintenance activities strictly comply with safety protocols for handling highly corrosive materials (Oleum, SO3).
• Permit Systems: Enforce the Permit to Work (PTW) system, Lockout/Tagout (LOTO), and confined space entry protocols.
• Regulatory Adherence: Ensure maintenance compliance with Factory Inspectorate, GPCB (Gujarat Pollution Control Board), and PESO regulations.

4. Inventory & Vendor Management

• Spares Management: Maintain optimum inventory levels for critical spares, specifically for acid-handling equipment, to prevent production delays.
• Local Vendor Coordination: Identify and liaise with reliable contractors and engineering vendors within the Surat/South Gujarat industrial ecosystem for specialized fabrication, machining, and emergency repairs.
• Budgeting: Prepare and control the annual maintenance budget (CAPEX and OPEX).

5. Team Leadership

• Manage, train, and mentor a team of mechanical fitters, electricians, instrumentation technicians, and contract labor.
• Drive a culture of "Safety First" and continuous improvement (5S, Kaizen) on the shop floor.

Qualifications & Experience

Education: B.E. / B.Tech in Mechanical or Chemical Engineering.

Experience:

• Minimum 2 years of core maintenance experience in continuous process chemical plants.
• Must have at least 2 of experience specifically in chemical manufacturing plant.
• Technical Skills:
• Expertise in the maintenance of equipment handling highly corrosive and toxic chemicals.
• Familiarity with CMMS (Computerized Maintenance Management Systems) or SAP PM module.
• Strong knowledge of metallurgy and corrosion-resistant materials (e.g., SS316L, Hastelloy, PTFE-lined equipment).

Language: Fluency in Gujarati and Hindi is highly preferred for effective shop-floor communication; proficiency in English for reporting.

Key Competencies

• Strong crisis management and troubleshooting skills.
• Ability to work under pressure in a fast-paced chemical manufacturing environment.
• Excellent leadership, communication, and inter-departmental coordination skills.