Deputy Manager - Maintenance

Designation Deputy Manager - Maintenance Function Product Supply Organization Location Barabanki Reporting To Senior Manager - Engineering Job Description 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.