Job Description:

We are looking for a Plant Maintenance Head. We need people who can handle 20-30 plants, and all maintenance people will report to you. You need to take care of all plants, implement preventative and corrective actions, ensure compliance with safety standards, collaborate on plant management strategies, oversee plant maintenance operations, and manage MTBF/MTTR reduction.

Head - Plant Maintenance:

Industry: Automotive - Tier-1 Auto Component

Function: Plant Engineering & Maintenance

Designation: Head - Maintenance / Plant Engineering

Level: DGM / GM

Reporting To: Plant Head / Operations Head

Position Summary:

The Plant Maintenance Head will be responsible for leading the complete maintenance and engineering function of a high-volume automotive Tier-1 manufacturing plant. The role will ensure high equipment availability, reliability, productivity, safety and cost efficiency through preventive, predictive and breakdown maintenance systems. The incumbent should have strong experience in automotive manufacturing, TPM, Total Productive Maintenance, AM, PM, OEE, MTBF/MTTR, Kaizen, Lean Manufacturing and plant engineering, with proven capability to manage critical production equipment and maintenance teams.

Key Responsibilities:

1. Plant Maintenance Management :

- Lead complete Mechanical, Electrical, Utilities and Equipment Maintenance activities.

- Ensure maximum machine availability and minimum unplanned downtime.

- Develop and implement preventive, predictive and breakdown maintenance systems.

- Establish maintenance standards, checklists, SOPs and equipment health monitoring systems.

- Drive MTBF improvement and MTTR reduction.

- Ensure critical spare-parts availability and effective inventory management.

2. TPM / Total Productive Maintenance:

- Drive TPM implementation across the plant.

- Strengthen Autonomous Maintenance (AM) and Planned Maintenance (PM) systems.

- Lead TPM pillars including Focused Improvement, Planned Maintenance, Quality Maintenance and Safety.

- Improve OEE, equipment reliability and machine utilization.

- Promote Kaizen and continuous improvement initiatives.

3. Equipment & Production Engineering:

- Ensure reliability of critical production equipment, assembly lines and special-purpose machines.

- Support new machine installation, commissioning and qualification.

- Review machine specifications and maintenance requirements for new projects.

- Lead equipment modification, automation and productivity improvement projects.

- Identify opportunities for Low-Cost Automation (LCA) and Industry 4.0-based maintenance solutions.

4. Utilities Management:

- Manage plant utilities including: Compressors, DG sets, Electrical systems, HVAC, Chillers, Boilers, Pumps, Water systems, ETP/STP, and Fire-fighting systems.

- Ensure uninterrupted and cost-effective utility supply.

- Drive energy conservation and utility-cost reduction initiatives.

5. Maintenance Planning & Cost Control:

- Prepare annual maintenance budgets and CAPEX plans.

- Control maintenance costs without compromising equipment reliability.

- Develop annual shutdown and major overhaul plans.

- Monitor maintenance expenditure, spare consumption and contractor costs.

- Implement cost-reduction initiatives through localization, refurbishment and VA/VE.

6. Safety & Compliance:

- Ensure compliance with all statutory requirements related to plant engineering and maintenance.

- Maintain electrical, fire, pressure-vessel and other statutory compliance.

- Implement strong LOTO (Lockout/Tagout) practices.

- Ensure safe maintenance practices and contractor safety.

- Participate in EHS audits and corrective-action implementation.

7. Team Leadership:

- Lead and develop the plant maintenance and engineering team.

- Define manpower requirements, skill matrices and competency-development plans.

- Train teams on TPM, RCA, problem-solving and preventive maintenance.

- Build a strong culture of ownership, discipline and continuous improvement.

- Manage external maintenance contractors and service providers.

8. Breakdown & Root Cause Analysis:

- Lead critical breakdown analysis and permanent corrective actions.

- Apply 5 Why, Fishbone, FMEA and RCA methodologies.

- Establish preventive actions to avoid recurrence.

- Monitor chronic equipment problems and develop long-term reliability solutions.

9. Digital & Smart Maintenance:

- Implement CMMS/SAP-based maintenance systems.

- Introduce condition monitoring and predictive maintenance.

- Utilize data analytics for equipment failure prediction.

- Drive digital dashboards for OEE, downtime, MTBF, MTTR and maintenance cost.

- Support Industry 4.0 and smart-factory initiatives.

Key Performance Indicators:

- Machine Availability, OEE, MTBF / MTTR, Breakdown Hours, Preventive Maintenance Compliance, Planned vs. Unplanned Maintenance, Maintenance Cost per Unit, Spare Parts Inventory, Utility Cost, Energy Consumption, Repeat Breakdown Rate, Equipment Reliability, Safety Compliance, TPM / AM / PM Implementation, CAPEX and Project Delivery.

Required Experience & Qualifications:

- B.E/B.Tech in Mechanical / Electrical / Mechatronics / Production Engineering.

- Typically 15-20+ years of experience, with significant experience in automotive manufacturing.

- Strong experience in Tier-1 automotive component manufacturing preferred.

- Experience managing maintenance for high-volume production plants.

- Strong knowledge of TPM, AM, PM, OEE, RCA, FMEA, Kaizen, Lean Manufacturing and Six Sigma.

- Hands-on experience with SAP PM / CMMS preferred.

- Experience in plant expansion, new equipment installation and commissioning.

- Strong exposure to automation, PLCs, robotics and electrical systems preferred.

Preferred Industry Background:

Candidates from automotive Tier-1 organizations involved in: Engine & transmission components, Rubber & hose components, Metal components, Brake components, Forgings / castings, Machining, Sheet metal, Auto electricals, Injection moulding, Assembly systems, Hydraulic / pneumatic systems.

Ideal Candidate Profile:

The ideal candidate will be a strong plant engineering and maintenance leader with proven experience in automotive Tier-1 manufacturing, capable of improving equipment reliability, reducing breakdowns, driving TPM and OEE, controlling maintenance costs and building a highly skilled maintenance organization.

Key Keywords:

TPM | AM | PM | OEE | MTBF | MTTR | RCA | FMEA | Kaizen | Lean | SAP PM | CMMS | Industry 4.0 | Predictive Maintenance | Automation | Utilities | CAPEX | LOTO