Senior Maintenance Engineer - Plant Maintenance (Heavy Engineering & Fabrication)

Key Responsibilities:

Maintenance Operations:

- Plan, organize, and supervise preventive, predictive, corrective, and breakdown maintenance activities to ensure uninterrupted production.

- Maximize machine availability while minimizing equipment downtime and maintenance costs.

- Prioritize maintenance activities based on production requirements and equipment criticality.

- Lead daily maintenance planning meetings and ensure timely execution of maintenance schedules.

- Conduct Root Cause Analysis (RCA) for recurring equipment failures and implement sustainable corrective and preventive actions.

Preventive & Predictive Maintenance:

- Develop, implement, and continuously improve Preventive Maintenance (PM) schedules for all critical manufacturing equipment.

- Monitor PM compliance and identify opportunities to improve equipment reliability.

- Establish equipment maintenance history and reliability improvement programs.

Equipment & Utilities Maintenance:

Lead maintenance activities for:

- Welding and cutting machines

- Hydraulic and pneumatic systems

- Gearboxes, motors, pumps, compressors, and blowers

- EOT cranes and material handling equipment

- Fabrication machinery and production equipment

- Industrial utilities and supporting infrastructure

- Electrical systems associated with plant machinery

Reliability & Continuous Improvement:

- Drive TPM, 5S, Kaizen, and Lean Maintenance initiatives across the plant.

- Improve equipment reliability through predictive maintenance and condition monitoring.

- Identify opportunities to reduce downtime, maintenance costs, and energy consumption.

- Recommend and implement equipment modifications to improve productivity and operational efficiency.

Planning & Coordination:

- Coordinate closely with Production, Quality, Purchase, Stores, Projects, and Engineering teams.

- Plan shutdown maintenance and annual maintenance activities.

- Ensure availability of critical spare parts, maintenance consumables, and specialized tools.

- Coordinate with external vendors for AMC, inspections, repairs, calibration, and servicing.

Projects & Plant Expansion:

- Support installation, commissioning, relocation, and modification of machinery and utilities.

- Participate in plant expansion, automation, and capacity enhancement projects.

- Provide technical support during equipment procurement and commissioning.

Cost & Budget Management:

- Prepare and manage annual maintenance budgets.

- Monitor maintenance expenditure and optimize maintenance costs without compromising reliability.

- Manage CAPEX proposals related to equipment upgrades and new machinery.

Documentation & Compliance:

- Maintain maintenance records, equipment history, SOPs, PM checklists, drawings, manuals, and calibration records.

- Ensure compliance with statutory regulations, company standards, LOTO procedures, and safety requirements.

- Drive timely closure of internal and external audit observations.

Key Performance Indicators (KPIs):

- Machine Availability ≥ 95%

- Reduction in equipment breakdown hours

- Improvement in Mean Time Between Failures (MTBF)

- Reduction in Mean Time To Repair (MTTR)

- Preventive Maintenance Compliance

- Maintenance Cost Optimization

- Critical Spare Parts Availability

- Reduction in Repeat Equipment Failures

- Energy Efficiency Improvement

- Safety Compliance and Zero Lost Time Incidents

Technical Competencies:

The ideal candidate should possess strong hands-on knowledge of:

- Preventive, predictive, and breakdown maintenance

- Mechanical and electrical maintenance practices

- Hydraulic and pneumatic systems

- Welding and cutting machinery

- Gearboxes, motors, pumps, compressors, and rotating equipment

- EOT cranes and material handling systems

- Fabrication machinery maintenance

- Maintenance planning and scheduling

- Spare parts planning and inventory management

- Root Cause Analysis (RCA)

- TPM, 5S, Kaizen, and Lean Manufacturing

- Machine installation and commissioning

- Equipment reliability and condition monitoring

Preferred Industry Background:

- Heavy Engineering

- Pressure Vessel Manufacturing

- Process Equipment Manufacturing

- Oil & Gas Equipment

- Boiler Manufacturing

- Industrial Burners & Combustion Systems

- Steel & Metal Fabrication

- EPC Manufacturing

- Process Plants

- Industrial Machinery Manufacturing