Head - Electrical & Mechanical Maintenance

Head - Electrical & Mechanical Maintenance (12-17 yrs)

1. Purpose of the Role:

- The Head - Engineering is responsible for leading the end-to-end Engineering and Maintenance function at Vizag.

- The role ensures Safety, reliability, and efficiency of Plant Operations through world-class Maintenance practices, strong Engineering governance, and full compliance with statutory, corporate, and group safety standards.

- This role plays a critical part in maximizing Manufacturing output by ensuring high equipment availability, excellent Plant upkeep, and effective execution of Capital expenditure projects, while building a highly capable and motivated Engineering team.

2. Direct Reports:

- Deputy Manager - Engineering (1) (expandable with future capacity additions)

3. Dimensions of the Position:

- This position is accountable for establishing, implementing, and continuously improving the Engineering and Maintenance management systems for the AR plants, including ownership of Capital expenditure planning and execution, with a strong focus on achieving world-class plant reliability, safety, and infrastructure excellence.

3.1. HSE Governance and Compliance:

- Ensure implementation and sustenance of all HSE standards across Engineering, Maintenance, Utilities, and Contractor activities.

- Institutionalize Risk Assessment (RA), PTW, LOTO, and safe practices for high-risk engineering jobs.

- Ensure full statutory and legal compliance related to engineering functions.

- Drive a proactive safety culture within the engineering and contractor workforce.

3.2. Quality - Plant Reliability & Asset Management:

- Drive Preventive and Predictive Maintenance frameworks to enhance equipment reliability and plant availability.

- Lead Root Cause Analysis for critical failures and implement sustainable corrective actions.

- Ensure upkeep and long-term integrity of plant assets including machinery, utilities, buildings, infrastructure, and roads.

- Use data-driven reviews to reduce breakdowns and improve asset performance.

3.3. Delivery - Reliability, Projects & Energy Management:

- Improve MTBF and MTTR through structured reliability reviews and corrective actions.

- Plan and execute Capex projects on time, within budget, and as per technical standards.

- Lead plant-wide energy management and energy-saving initiatives.

- Ensure engineering readiness to support uninterrupted production and future expansion.

3.4. Cost - Maintenance Budgeting & Resource Optimization:

- Prepare and control annual maintenance budgets for plant, utilities, and infrastructure.

- Optimize spare parts inventory to balance availability and inventory cost.

- Drive cost savings (V Save) through reliability improvement and engineering initiatives.

3.5. People - Team Leadership & Capability Development:

- Build and sustain a high-performing engineering team aligned with current and future plant needs.

- Drive training, multi-skilling, and succession planning within the team.

- Foster a culture of safety, ownership, discipline, and continuous improvement.

4. Key Area Results:

4.1. HSE Performance & Compliance:

- Zero major safety incidents in engineering activities.

- 100% compliance with internal and external HSE audits.

- Full statutory compliance with no legal non-conformities.

4.2. Engineering Management & Plant Reliability:

- 95% adherence to Preventive Maintenance schedules.

- Continuous improvement in MTBF and reduction in MTTR.

- Reduction in breakdown hours year-on-year.

4.3. Plant Reliability & Engineering Effectiveness:

- High equipment availability to support manufacturing delivery.

- 100% timely calibration of instruments and control devices.

- Capex execution on time and on cost.

- Quick resolution of critical engineering problems using RCA.

4.4. Cost Efficiency & Resource Optimization:

- Maintenance costs within approved budgets.

- Reduction in energy consumption through conservation initiatives.

- Optimum spare inventory without impacting plant uptime.

4.5. People Capability & Engineering Culture:

- Annual training plan and skill development for engineering team.

- Implementation of 5S, visual management, and work standardization.

- Strong team engagement, discipline, and succession readiness.

5. Experience Requirements:

- Min 11+ Yrs of experience in leading Electrical, Mechanical, Instrumentation, and Civil maintenance in a manufacturing environment.

- Experience handling annual maintenance and capex budgets of INR 60-80 million.

- Exposure to TPM, Lean Engineering, Autonomous Maintenance, and reliability practices.

- Experience with mixers, conveyors, gas-fired ovens, EOT cranes, PLC, and SCADA systems.

- Vendor and contract workforce management experience.

- Capex planning and execution experience.

6. Knowledge Requirements:

- Strong knowledge of TPM, reliability practices, and maintenance excellence frameworks.

- Understanding of industrial safety standards and statutory requirements.

- Knowledge of problem-solving tools (RCA, 8D, Why-Why, Fish bone).

- Project management and cost control knowledge.

- Understanding of rotating equipment, material handling systems, PLC/SCADA, and utilities.

7. Skills & Behavioural Competencies:

- Strong leadership and team-building capability.

- Analytical, data-driven problem-solving approach.

- Excellent planning, coordination, and stakeholder management skills.

- Strong communication and interpersonal skills.

- Vendor negotiation and management capability.

- High ownership and result orientation.

8. Problem Solving & Complexity:

- Handle complex technical problems impacting plant reliability and production.

- Improve engineering systems through cross-functional collaboration.

- Lead multi-stakeholder capex projects ensuring technical and financial effectiveness.

- Take critical engineering decisions under production, safety, and resource pressures.

9. Qualifications:

- Bachelor's/PG degree in Engineering stream (preferably Electrical/ Mechanical / Mechatronics)