Role Purpose:

The GM - Maintenance is a plant-critical leadership role, responsible for ensuring high asset reliability, minimal breakdowns, strong safety performance, and disciplined preventive & predictive maintenance systems across all electrical, mechanical, and utility assets.

This role is not firefighting-oriented. It is designed for a leader who builds robust systems, reliability culture, and technology-enabled maintenance practices, while remaining closely connected to the shopfloor.

Key Responsibilities:

1. Maintenance Strategy & Leadership

- Define and execute an integrated preventive and predictive maintenance strategy across steel melting, forging, rolling, heat treatment, cranes, and utilities.

- Lead a combined electrical + mechanical + utility maintenance team, ensuring clear accountability, skill development, and strong discipline.

- Build second-line capability and reduce single-point dependencies within the maintenance organization.

2. Asset Reliability & Breakdown Reduction

- Own plant-wide breakdown reduction, with a sharp focus on steel melting operations and EOT cranes, which are current critical assets.

- Drive root cause analysis (RCA) for all major failures using structured tools (5-Why, FMEA, fishbone) and ensure permanent corrective actions.

- Monitor and improve MTBF, MTTR, downtime hours, and maintenance cost trends.

3. Electrical Systems, Power Quality & Automation

- Oversee maintenance of transformers, substations, panels, drives, motors, furnaces, cranes, and power distribution systems.

- Ensure power quality monitoring and stability, maintaining KISCO's strong performance in this area.

- Provide leadership on PLCs, automation, and control systems through team guidance and vendor coordination (hands-on coding not mandatory).

4. Mechanical Systems & Predictive Maintenance

- Ensure reliable operation of furnaces, rolling mills, forging equipment, hydraulic and pneumatic systems, cranes, and rotating equipment.

- Effectively utilize and further strengthen predictive maintenance tools such as vibration analysis, thermography, oil analysis, and condition monitoring.

- Encourage investment in advanced reliability tools and technologies, provided they are effectively implemented and used.

5. Shutdown Planning & Project Coordination

- Plan and execute monthly plant shutdowns in close coordination with PPC and Projects teams.

- Own maintenance execution during shutdowns with a strong focus on safety, quality, and timeline adherence.

- Support new project commissioning and stabilization, ensuring smooth transition from project phase to steady-state operations.

6. Safety Ownership

- Act as a strong safety leader, with zero tolerance for unsafe practices.

- Enforce electrical safety, crane safety, LOTO, confined space, and high-risk maintenance procedures.

- Empower teams to stop work where safety is compromised and embed safety into daily maintenance behavior.

7. Cost Control, Spares & Inventory

- Drive maintenance cost optimization without compromising asset health or safety.

- Focus on improving spares inventory turns, critical spares identification, and rationalization.

- Commercial negotiations and purchasing will be handled by the Commercial GM; however, technical specifications and lifecycle decisions remain with this role.

8. Authority & Decision Rights

Full authority to:

- Approve planned shutdowns (in coordination with PPC)

- Approve spares procurement and AMC renewals

- Approve replacement capex for end-of-life equipment

- New project capex approvals remain with MD.

Key Performance Indicators (KPIs):

- Reduction in unplanned breakdowns and downtime

- Maintenance cost control and inventory turns

- Crane availability and safety performance

- Effectiveness of preventive & predictive maintenance

- Safety metrics (zero serious incidents)

- Stabilization of new equipment/projects

Candidate Profile:

Qualifications & Experience:

- BE/BTech in Mechanical / Electrical / Electrical & Mechanical Engineering

- 15+ years of experience in maintenance roles within heavy manufacturing (preferrably steel)

- Proven experience managing both electrical and mechanical maintenance

- Exposure to steel plants preferred; strong heavy manufacturing experience acceptable

- Leadership & Working Style

- 50% shopfloor engagement / 50% system building

- Strong team leader with hands-on credibility

- Comfortable working directly with MD and cross-functional leaders

Language & Communication:

Hindi essential; Punjabi desirable

English & Hindi for white-collar coordination and reporting