Maintenance Manager at IFFCO

Req ID: 3121

Job Summary

• To lead and oversee seamless maintenance operations including electrical, mechanical, civil and utilities maintenance and ensure that that there is no production loss due to non-availability of machinery

Roles & Responsibilities

• Develop the short term and long term maintenance strategy for the plant in line with the overall operations strategy
• Formulate end to end maintenance planning framework and prepare preventive and predictive maintenance mechanisms in alignment with the production targets and schedules
• Participate in the budgeting exercise and provide inputs on maintenance cost estimate and other utility costs
• Devise and implement safety improvements, capacity enhancements, cost optimization and process improvement (ISO, Kaizen, 5S, 6 SIGMA etc.) practises at the plant
• Devise mechanisms and strategies for effluent treatment and waste disposal at the plant Operational
• Ensure end to end availability and upkeep of plant machinery, perform machine lifecycle assessment and oversee repairs as and when required
• Maintain facility performance standards by maximizing equipment reliability/productivity and utilizing process tools and knowledge of system capability to set and achieve performance standards
• Monitor maintenance budget utilization and analyse variance to take corrective action
• Ensure 100 % safety for men and machines from undue accidents happening due to machine health, installation and operations
• Ensure documentation of Standard Operating Procedures (SOPs) for the maintenance and repair work and ensure maintenance of optimum inventory levels as per plant goals
• Identify critical spares and solicit timely purchase requests. Follow up for deliveries with purchase teams and maintain an inventory of spares required for various machines to ensure availability of critical spares and control
• Plan for preventive maintenance and planned plant shut down schedules in consultation with the Operations Head and regularly monitor the preventive maintenance and breakdown maintenance reports
• Ensure availability of plant services like DG Back up, Battery backup, ETP, Civil infrastructure, Sewage and drainage. Also ensure compliance to legal and environmental norms associated with the plant services 14. Ensure timely and accurate data recording for all breakdowns capturing downtime, reason for breakdown, resolution etc.
• Prepare shift report capturing breakdown duration, nature of breakdown, time to resolve, nature of solutions etc. for the breakdowns handled; Share the report with the seniors for consolidation
• Analyse recurring issues and breakdowns in the shift and propose actions to the Head Operations
• Initiate corrective actions for all unplanned breakdowns in minimum time to prevent any production loss due to the unavailability of equipment
• Ensure periodic evaluation of all equipment suppliers, AMC vendors etc.
• Identify and implement process improvement opportunities, monitor effectiveness of initiatives and take corrective action
• Benchmark the best practices and analyse ideas generated by employees to improve existing processes and ensure cost reduction and productivity enhancement
• Review compliance to all production, quality and safety standards and finalize action plans to improve the level of compliance
• Ensure creation of a safe working environment through adherence to safety norms and implementation of required safety practices People Management
• Allocate work to subordinates, nominate for training as per guidelines, conduct performance reviews and manage leave and overtime to ensure efficiency.
• Participate in the identification of training and development initiatives for all subordinates
• Drive the engagement and satisfaction of the team through holding periodic meetings to discuss the achievements and address any employee issues and/or concerns

KPIs:

• % adherence to Equipment Maintenance Budget Plan
• % decrease in machine downtime
• Number of cases of stock out of Spare parts
• % adherence to the plan for hazardous wastes disposal
• % reduction in repeated machinery failure
• MTTR and MTBF
• % compliance with the regulations laid down by statutory bodies for environment related compliances (air, water, land, pollution etc.) 8. % achievement of cost reduction targets for the department as per plan

Qualification

• Engineering Degree with specialization in in Mechanical/Electrical Engineering.

Work Experience Requirement

• Minimum 7+ years of plant maintenance experience with at least 4 years as a Maintenance manager, preferably in a similar industry

Competencies:

• Self and Team Management
• Driving Results
• Planning & Decision Making
• Spare Parts Inventory Management
• Engineering and Maintenance Standards
• Schedule Management
• Conflict Management
• Negotiating Skills
• Change Management
• Production Planning
• Production, Quality Control and Procurement Processes
• Strategic Thinking
• Ownership and Accountability
• Safety Procedures and Norms