JOB DESCRIPTION - L4 Position

SECTION HEAD - Maintenance Strategy & Asset Management (All Shops)

(Weld Shop | Paint Shop | Assembly Shop | Engine | Transmission)

Automobile Manufacturing OEM

Experience: 15 - 20 yrs

Location: Chennai

Role Definition:

The Head of Maintenance Strategy & Asset Management ensures all equipment including robots, conveyors, jigs, fixtures, and Special purpose machines operates at maximum uptime, 100% safety, and high performance through structured PM programs, sensor-based health monitoring, and data-driven diagnostics.

This role is focused on maintenance planning, reliability engineering, analytics, digital tools, long-term asset health, and budgets and ensures compliance with OEM, legal, safety, and customer standards.

- Act as Deputy BISO (Business Information Security Officer) for the organization & work with Global IT teams to ensure Information Security at shopfloor level

- Lead Digital Initiatives with respect to production equipment to enhance efficiency & uptime.

- Lead Maintenance Strategies like Industry 4.0, Predictive Maintenance, Sustainability Initiatives etc.

Reports to: Head of Plant Engineering, Manufacturing Engineering & EHS

Overall Purpose of the Role:

- Lead the Reliability Centred Maintenance function across Weld Shop, Paint Shop, Assembly Shop, Engine shop and transmission shop.

- Deliver world-class equipment reliability, increase MTBF, reduce MTTR, and maintain zero-accident operations.

- Develop and execute PM, CBM, predictive maintenance, Industry 4.0 initiatives, and continuous improvement strategies.

- Lead a multi-skilled team while driving best practices, standards, and capability-building.

- Ensure all equipment, facilities, and automation systems meet production requirements with optimal cost, quality, and safety.

- Support new model launches and ensure equipment readiness.

Key Responsibilities:

1. Strategy & Development:

- Develop RCM, CBM, and Industry 4.0-based strategies for all equipment.

- Align maintenance plans with future technologies, model launches, and volume ramp-up.

- Support strategic business initiatives such as new projects, capacity expansion, localization etc.

- Build a long-term roadmap for Zero break down strategy, CMMS, digital twin, and predictive analytics.

2. General & Task Management:

- Lead preventive, predictive, and breakdown maintenance for all welding robots, painting systems, assembly lines, Engine assembly, Transmission assembly and testing equipment.

- Create, maintain, and monitor the PM/CBM/PdM schedules and ensure 100% adherence.

- Establish and sustain maintenance data systems (SAP/CMMS).

- Ensure calibration, statutory compliance, and lifecycle management of equipment.

- Manage spare parts and consumable strategies including localization and cost optimization.

- Implement digital tools: IoT sensors, condition monitoring, CMMS dashboards, Power BI analytics, robot diagnostics, etc.

- Lead equipment introduction from specification finalization to installation, commissioning, and handover.

- Drive safe disposal of obsolete equipment as per corporate and statutory norms.

- Drive cross-functional problem solving with ME, Production, Quality, Safety and Projects.

- Support TPM Initiatives.

3. Safety, Compliance & Risk Management:

- Ensure 100% compliance with IMS (Integrated Management system - ISO 14001:2015; ISO 45001:2018; ISO 50001:2018) & IATF16949, legal and corporate standards.

- Implement risk assessments (HIRA/MSRA), LOTO, energy isolation and contractor management.

- Ensure statutory certification for Lifting tackles, cranes, electrical systems, etc.

- Promote a strong culture of safety, discipline, quality, and housekeeping (5S).

4. People & Capability Management:

- Lead and develop a large, multi-disciplinary team of mechanical, electrical, Instrumentation, powertrain (Test beds), automation, and robotics engineers.

- Build skill matrices, competency roadmaps, and continuous training programs (robotics, PLC, IoT, TPM).

- Set departmental KPIs to track preventive performance.

- Coach and mentor successors for leadership roles.

5. Financial & Budget Control:

- Own the full maintenance budget, including CapEx, OpEx, spares, AMC, contractor manpower.

- Prepare annual budgets, forecasts, and Capex proposals.

- Achieve maintenance cost optimization without compromising safety and machine availability.

- Build long-term strategies for energy savings, AMC reduction, and lifecycle cost improvement.

6. Relationship & Stakeholder Management:

- Work closely with Production, Quality, ME, Safety, Procurement, Finance, Projects, and external partners.

- Collaborate with equipment manufacturers, service providers, and technology partners.

- Communicate the impact of market/technology changes and recommend solutions.

- Conduct internal safety audits and regulatory inspections.

7. Self-Management & Leadership Behaviour:

- Demonstrate resilience, strategic thinking, and a proactive approach to challenges.

- Maintain high personal performance and set a strong example for the team.

- Drive a culture of accountability, ownership, collaboration, and continuous improvement.

Skills & Attributes:

- Strong leadership and team management capability.

- Excellent communication, presentation, and stakeholder engagement skills.

- Strong technical understanding of mechanical, pneumatics, hydraulics electrical, controls, robotics, PLC, automation, etc.

- High competency in problem-solving, decision-making, and data-driven maintenance.

- Expertise in lean manufacturing, TPM pillars, and maintenance excellence frameworks.

Qualifications & Experience:

- Bachelor's degree in mechanical/electrical/Electronics/Mechatronics Engineering (mandatory).

- 15+ years of experience in Maintenance, including at least 3 - 5 years in leadership roles.

- Strong experience across Weld Shop, Paint Shop, Assembly, Powertrain (minimum 2 essential).

- Exposure in robots (KUKA, Yaskawa, Fanuc), PLCs (Allen Bradley, Mitsubishi, Siemens), Controls, Instrumentation, Machine tools.

- Knowledge of FMEA, Lean Manufacturing, Kaizen, Six Sigma.

- Proficiency in Microsoft Office, SAP /CMMS tools, and preferred digital platforms.