Mechanical Maintenance Head

Head of Mechanical Maintenance – Steel Wire Manufacturing1. Position Details

• Department: Mechanical Maintenance
• Reports To: SBU Head / Unit Head
• Experience: 15–20 years in steel wire or similar manufacturing industry
• Qualification: Degree / Diploma in Mechanical Engineering

2. Job Purpose

To lead mechanical maintenance operations, ensuring equipment reliability, optimum plant availability, safe operations, cost efficiency, and uninterrupted production. The role focuses on preventive maintenance, breakdown reduction, equipment improvement, team development, and standardization of maintenance practices across BWIL's HC, MS, and Specialty Wire units.

3. Key Responsibility Areas (KRAs)

A. Strategy and Planning

• Develop the annual maintenance plan and budget in alignment with the ABP and business objectives.
• Establish annual maintenance calendars, preventive maintenance schedules, and common PM checklists across all units.
• Identify equipment improvement opportunities to enhance reliability, productivity, and machine life.

B. Maintenance Execution and Reliability

• Implement preventive, predictive, and condition-based maintenance programs.
• Ensure timely execution of maintenance schedules, shutdowns, overhauls, and emergency breakdown repairs.
• Conduct RCA of repetitive and critical breakdowns and implement CAPA.
• Monitor equipment performance and drive improvements in MTBF, MTTR, and downtime.

C. Cost and Spares Management

• Control maintenance expenditure, including spares, consumables, repairs, refurbishment, and manpower costs.
• Ensure availability of critical spares and optimize inventory levels.
• Identify cost-saving opportunities through refurbishment, standardization, and equipment modifications.

D. Coordination and Governance

• Coordinate with Production, Quality, Procurement, Stores, and senior management to ensure smooth plant operations.
• Conduct daily, weekly, and monthly maintenance performance reviews.
• Monitor KPIs, maintenance schedules, work orders, and budget utilization.

E. People Development and Continuous Improvement

• Lead, mentor, and develop maintenance engineers, supervisors, and technicians.
• Implement TPM, 5S, best practices, and digital maintenance tools such as CMMS and condition monitoring.
• Drive machine and process improvement projects to enhance productivity and quality.

F. Safety, Compliance and Standardization

• Ensure compliance with safety procedures, LOTO, permit-to-work systems, and applicable statutory and environmental requirements.
• Implement standardized maintenance procedures and support internal audits across all units.
• Ensure timely closure of audit observations and corrective actions.

4. Key Performance Indicators (KPIs)

• Safety: Accidents, near misses, safety compliance, and environmental compliance.
• Reliability: Machine breakdown duration, unplanned downtime, MTBF, and MTTR.
• Preventive Maintenance: PM compliance, PMR, and maintenance schedule adherence.
• Breakdown Control: RCA completion, CAPA closure, and repeat breakdown reduction.
• Cost Control: Total maintenance cost, cost per tonne, spares cost, and budget variance.
• Utilities: Electricity, LPG, lubricants, and other applicable specific consumption.
• People Development: Technical training, employee productivity, and departmental attrition.
• Improvement Projects: ABP target achievement, cost savings, and equipment efficiency improvements.
• Inventory and Governance: Critical spares availability, work-order closure, and audit compliance.

5. Job Specifications

Qualification and Experience

• Degree / Diploma in Mechanical Engineering.
• 15–20 years of relevant experience, preferably in steel wire manufacturing.
• Proven experience in leading mechanical maintenance teams and managing plant equipment reliability.

Technical Skills

• Knowledge of wire drawing, annealing, coating, galvanizing, and related equipment.
• Strong understanding of mechanical drives, gearboxes, bearings, hydraulics, pneumatics, and rotating equipment.
• Knowledge of preventive maintenance, RCA, TPM, PLC-controlled equipment, and CMMS.
• Understanding of industrial safety standards and environmental regulations.

Leadership Skills

• Team leadership, manpower development, and cross-functional coordination.
• Maintenance budgeting, cost optimization, and spares management.
• Project management, troubleshooting, and continuous improvement.

6. Key Deliverables

• Improved equipment reliability and reduced unplanned downtime.
• Achievement of maintenance budget and ABP targets.
• Standardized maintenance systems across BWIL units.
• Improved safety, productivity, and maintenance team competency.
• Successful execution of equipment improvement and cost-reduction projects.

Performance Review: Performance shall be reviewed monthly and annually against approved KPIs, ABP targets, maintenance costs, equipment reliability, safety, and improvement initiatives.

Pay: ₹1,500,000.00 - ₹2,500,000.00 per year

Work Location: In person