Job Purpose:

To lead and manage the complete electrical maintenance function of the manufacturing plant, ensuring maximum equipment availability, minimum downtime, safe and reliable electrical operations, energy efficiency, statutory compliance, and cost-effective maintenance.

The role will be responsible for electrical maintenance strategy, team management, preventive and predictive maintenance, breakdown management, plant utilities, electrical infrastructure, CAPEX projects, energy management, and continuous improvement initiatives.

Key Responsibilities:

1. Electrical Maintenance Management:

- Lead the overall electrical maintenance activities across the plant.

- Ensure maximum availability and reliability of electrical systems and production equipment.

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

- Monitor critical equipment and identify potential failures before breakdown.

- Ensure timely resolution of electrical breakdowns to minimize production losses.

- Drive continuous improvement in electrical system reliability.

2. HT & LT Electrical Systems:

- Responsible for maintenance of HT/LT electrical distribution systems.

- Manage HT/LT panels, transformers, RMU, VCB, ACB, MCC, PCC and distribution boards.

- Ensure reliability of electrical cables, bus ducts, switchgear and protection systems.

- Monitor electrical load, power quality and system performance.

- Ensure proper functioning of electrical protection and interlocking systems.

3. Plant Utilities & Electrical Infrastructure:

- Oversee electrical maintenance of DG sets, transformers, UPS systems, battery banks, APFC panels, HVAC systems, air compressors, chillers, pumps, fire-fighting systems, plant lighting, earthing and lightning protection systems.

- Ensure uninterrupted power supply to critical production and utility systems.

4. Production Equipment & Automation:

- Provide electrical maintenance support for automated manufacturing equipment.

- Troubleshoot PLC, HMI, VFD, servo drives, sensors, motors, relays and control panels.

- Coordinate with Automation, Production and Process Engineering teams for equipment issues.

- Support equipment modification, improvement and automation projects.

- Coordinate with OEMs for critical equipment breakdowns and technical issues.

5. Preventive & Predictive Maintenance:

- Develop and implement annual/monthly preventive maintenance plans.

- Ensure 100% compliance with planned maintenance schedules.

- Implement predictive maintenance techniques such as thermography, insulation resistance testing, earth resistance testing, motor condition monitoring and transformer condition monitoring.

- Maintain equipment history and identify recurring failure patterns.

6. Breakdown Management & RCA:

- Lead critical electrical breakdown analysis and restoration.

- Conduct Root Cause Analysis (RCA/RCFA) for major and repetitive breakdowns.

- Develop and implement CAPA.

- Track MTBF, MTTR and breakdown hours.

- Drive initiatives to eliminate recurring electrical failures.

7. Energy Management:

- Monitor plant energy consumption and electrical demand.

- Drive initiatives for energy conservation and optimization.

- Improve plant power factor and reduce electrical losses.

- Monitor maximum demand and power quality.

- Identify and implement energy-saving opportunities.

- Coordinate with electricity utility providers and external agencies.

8. Safety & Statutory Compliance:

- Ensure compliance with applicable electrical safety regulations and statutory requirements.

- Ensure strict implementation of LOTO and electrical safety procedures.

- Conduct periodic electrical safety audits.

- Ensure proper testing and maintenance of protection systems.

- Coordinate statutory inspections and electrical approvals.

- Ensure safe working practices during HT/LT maintenance activities.

9. CAPEX & Project Management:

- Lead electrical engineering activities for plant expansion and CAPEX projects.

- Review electrical load requirements and distribution plans.

- Participate in technical evaluation and selection of electrical equipment.

- Supervise installation, testing and commissioning.

- Coordinate with consultants, contractors, OEMs and vendors.

- Ensure projects are completed within approved cost, quality and timelines.

10. Team Management:

- Lead a team of electrical engineers, supervisors and technicians.

- Plan manpower deployment and shift requirements.

- Define team KRAs and KPIs.

- Conduct technical training and competency development.

- Develop a strong troubleshooting and preventive-maintenance culture.

- Ensure effective communication between shifts and departments.

11. Spare Parts & Cost Control:

- Develop a critical electrical spare-parts strategy.

- Ensure availability of critical spares for uninterrupted plant operation.

- Optimize spare inventory and maintenance costs.

- Prepare and control the annual maintenance budget.

- Monitor AMC/service contracts.

- Manage OEM and vendor relationships.

12. Documentation & MIS:

- Maintain electrical equipment history and maintenance records.

- Prepare monthly maintenance reports and dashboards.

- Monitor equipment availability, OEE, MTBF, MTTR, breakdown hours, PM compliance, energy consumption, power factor and maintenance cost.

- Present maintenance performance and improvement plans to management.