Maintenance Head

Key Responsibilities

1. Strategic Reliability & Maintenance Execution

• Develop and execute a comprehensive Preventive Maintenance (PM) and Predictive

Maintenance (PdM) schedule to ensure equipment availability meets production targets.

• Implement condition-monitoring strategies, including vibration analysis, thermal imaging,

oil/lubrication analysis, and acoustic monitoring on heavy rotating machinery.

• Establish root-cause failure analysis (RCFA) protocols using 5-Why, Fishbone, or FMEA

methodologies following any critical breakdown, driving corrective actions to prevent

recurrence.

• Track, evaluate, and report maintenance KPIs: Mean Time to Repair (MTTR), Mean Time

Between Failures (MTBF), OEE, and scheduled compliance rates.

2. Plant Machinery & Heavy Asset Upkeep

• Size Reduction & Shearing Assets: Oversee wear management and rebuilds for heavy-duty

metal shredders (rotors, hammers, wear plates, anvils, and reject gates) and hydraulic

guillotine shears/balers.

• Separation & Sorting Lines: Maintain downstream non-ferrous and Automotive Shredder

Residue (ASR) separation units, including magnetic drum separators, eddy current

separators (ECS), induction sorters, air classifiers, and vibratory feeders.

• Heavy Hydraulics & Pneumatics: Direct troubleshooting and rebuilds of high-pressure

hydraulic power units (HPUs), valves, hydraulic cylinders, heat exchangers, and filtration

circuits.

• Material Handling & Yard Equipment: Supervise structural inspections, rope/chain

maintenance, and scheduled overhauls for EOT scrap-handling cranes, heavy excavators,

hydraulic mobile handlers, and weighbridge systems.

3. Inventory, Spares & Procurement Management

• Formulate and control the annual Maintenance Operating Budget (Opex) and Capital

Expenditure (Capex) for plant upgrades, rebuilds, and structural overhauls.

• Establish a critical spares matrix and maintain optimal inventory levels for rapid-wear

components (hammers, cutter blades, liner plates, heavy bearings, hydraulic seals, and spare

motors) to prevent stockout-induced downtime.

• Standardize equipment parts and create technical specifications for purchasing high-wear

metallurgical castings, mechanical drives, and fluid power components.

• Evaluate, negotiate, and manage Annual Maintenance Contracts (AMCs), external machine

shops, re-chroming/grinding services, and third-party diagnostic vendors.

4. Safety, Statutory Compliance & Housekeeping

• Champion industrial safety practices, including Lockout/Tagout (LOTO), confined space

entry, hot work permits, and line-break procedures during all maintenance activities.

• Ensure all pressure vessels, lifting tackles, EOT cranes, weighbridges, and electrical

installations strictly adhere to local statutory inspections, factory acts, and regulatory

standards.

• Implement 5S methodology and safe material staging within the central workshop,

oil/lubricant storage rooms, and scrap maintenance bays.

• Drive fire protection readiness across hydraulic power rooms, shredder enclosure fire-

suppression systems, and substation battery backup rooms.

5. Team Leadership & Contractor Supervision

• Lead, mentor, and upskill a multi-disciplinary team of mechanical & electrical engineers,

fitters, certified welders, and technicians.

• Conduct regular shift briefings, technical tool-box talks, and skill gap analyses to

continuously enhance in-house troubleshooting capabilities.

• Supervise external contractors and fabrication teams during major overhauls, relining

outages, or structural retrofits, ensuring adherence to quality and safety standards.