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.

What are the Critical success factors for the Role?

• Mandatory Qualification: B. Tech/B. E Electrical/Mechanical/Electronic Engineering OR Diploma in Engineering.
• Experience: Minimum 10 years for B. Tech candidates and minimum 15 years for Diploma candidates in FMCG/Food Processing industry with specialization in IMA Tea Bagging machines.
• Mandatory Skills: Preventive Maintenance, Breakdown Analysis, SAP, Vendor Management, TPM, Electrical & Mechanical Maintenance, Health & Safety Management.
• Language: Hindi and English.

What are the Desirable success factors for the Role?

• PLC/HMI/VFD troubleshooting, Lean Six Sigma, Reliability Engineering, RCA, ISO Internal Auditor certification, Energy Management and CAPEX project execution.