Manager - Mechanical Engineering

Job Description

Key Purpose of the Job (Position Summary)The position shall be responsible for all mechanical maintenance, upkeep and preservation of all equipment s in terms of mechanical aspects in the defined area and consequently ensuring availability of machinery and ensuring the maintenance expenses are within budget. The position will also be responsible to ensure predictive and preventive maintenance is done in an effective manner and within the prescribed timeframe in order to reduce the machine breakdowns and to enhance the operational efficiency. KEYPERFORMANCE AREAS

• Adherence to maintenance schedule and maintenance budget
• Reduction in down time (Hours and Numbers)
• Reduction in cost of maintenance (Stores, spares and repair maintenance cost)
• No. of machine under Autonomous Maintenance
• Improvement in Plant reliability index
• % Reduction in accidents and unsafe conditions
• 5 Score improvement
• No. of Improvement initiatives (SPARSH Machine, Kaizan, Hira etc.)
• Training man days with focus on capability building
• Adherence to DWM schedule.

KEY ACTIVITIES & RESPONSIBILITIESPlanning 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 BU head
• Prepare the plan for spares and consumables required for Mechanical maintenance
• Plan annual maintenance schedule in line with the annual plant shutdown plan

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 associates are familiar with required maintenance technique
• Regularly conduct training sessions for the shop floor associates 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 department colleagues of Manufacturing / Technology/ Quality & PPC of other dept to 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
• Seek support from Engg for major maintenance

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

Cost Management

• Maintain and control maintenance cost within budget
• Reduce maintenance costs by initiating cost saving measures and through innovative ideas

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

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

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

Improvement Projects

• Provide inputs and encourage team to work on improvement projects like Kaizen, QIP, 5S, Bol Bindaas, SPARSH, HIRA etc

Education and Experience RequiredEducation:Graduate in Engineering / B.E Mechanical Experience:Min 8 years,

Keyskills :
mechanicalinspectionroot cause analysisservice center operationssap isexternal auditanalysis reportsvibration analysismechanical maintenancepreventive maintenanceequipment installation