Job Purpose

To lead comprehensive mechanical maintenance operations for Alpha site production ensuring statutory compliance, maximum equipment reliability through predictive/preventive programs, shutdown management excellence and cost-effective maintenance strategies

Principal Accountabilities

1. Coordinate statutory authority visits (PESO, Boiler Inspectorate) ensuring compliance implementation and maintain statutory records for audit readiness.
2. Ensure smooth functioning of SO2/Hydro/Old Plant/ETP plants, reactors, furnaces, pumps and compressors as per design parameters through proactive monitoring.
3. Plan/implement preventive & predictive maintenance schedules using vibration analysis, thermography and oil analysis for all rotating equipment.
4. Organize shutdown maintenance activities, external agency audits (TUV, RINA) and ensure certification compliance.
5. Coordinate with Materials for critical spares inventory, emergency procurement follow-up and indigenization initiatives.
6. Authorize safety work permits as Maintenance Head, enforce LOTO compliance and champion zero-incident safety culture.
7. Ensure exemplary housekeeping/5S standards, attend weekly inter-departmental meetings and drive energy conservation initiatives.
8. Identify breakdown bottlenecks using root cause analysis, implement permanent solutions and prepare daily/monthly maintenance reports.
9. Conduct project costing, sustain high-performance engineering teams and generate Kaizen for continuous improvements.

Major Challenges

• Executing complex preventive maintenance during continuous operations without production impact.
• Managing multi-agency statutory compliance while optimizing maintenance budgets.
• Coordinating major furnace/reactor shutdowns with minimal production losses.

Decisions

Independent Decisions:

• Maintenance strategy formulation and manpower deployment.
• Preventive schedules, safety permit authorizations and cost-saving initiatives.
• Contractor selection and minor CAPEX maintenance projects.

Requires Approval:

• Major CAPEX equipment replacements.
• Extended shutdowns affecting production targets.
• Statutory compliance capital investments.

Interactions

Internal Clients 

• Plant Incharge (maintenance-production coordination)
• Production Supervisors (breakdown response)
• Materials/Procurement (spares optimization)
• Safety/ISO teams (compliance partnership).

External Clients              

• Statutory authorities, OEMs, certifying agencies. 

Dimension Skills

Financial Dimensions 

• Annual maintenance budget responsibility (?10-15 Cr).
• Direct P&L impact through equipment uptime optimization.    

Other Dimensions

• Supervises 35-50 maintenance personnel across shifts.
• Scale of Impact: Complete mechanical maintenance for Alpha site operations.

Knowledge

Educational Qualifications   

a)   Qualifications

• Minimum Qualification: B.E./B.Tech Mechanical Engineering

b)   Work Experience

• 5-7 years chemical industry maintenance with 3+ years supervisory experience.

Functional Competencies

• Predictive maintenance technologies (vibration, NDT, thermography)
• Skill/Competency to operate various condition monitoring Gadgets/tools and analysis.
• CMMS/ERP systems (SAP PM, Maximo)
• Root cause analysis (RCA, FMEA, 8D methodology)
• Rotating equipment expertise (pumps, compressors, furnaces)
• Shutdown critical path management
• ISO 9001/14001/OHSAS compliance