Maintenance Manager

As Manager - Maintenance, you part of plant leadership team at Malanpur and will lead the engineering services function and handle projects related to Productivity Improvement, Energy Management, Utility Improvement etc.

Key Responsibilities:

• Shall be responsible for maintenance both preventive and breakdown and troubleshooting, upkeep of various Chemical Process Equipments like Fat Splitting Plant, Fatty Acid Distillation Plant, Glycerine Evaporation Unit, Mechanical Vapor Compressors etc.
• Shall be responsible for the maintenance, troubleshooting and upkeep of various mechanical utilities like Compressors, Boilers, Steam Generators, Water and Brine Chillers, Diesel Generators of Large Capacities, Transformers, Micro Turbines, Evaporator Condensers, ETP/STP etc.
• Shall be responsible for the maintenance, troubleshooting and upkeep of mechanical, piping, carrying process water, ETP sludge, drain, oil, distillates, Glycerine and various other by products.
• Shall be responsible for the maintenance, troubleshooting and upkeep of various process plants like Soap Making equipments comprising conventional Soap Saponification, Kettles and Crutchers, Heat Exchangers, Barometric Condensers, Driers Bucket Elevators & Continuous Saponification Plant, etc.
• Shall be responsible for the maintenance, troubleshooting and upkeep of manufacturing setup like Toilet Soap manufacturing comprising Simplex / Duplex / Vacuum Plodders, Roll Mills, Soap Stampers, Soap Wrapping Machines, Soap Banding machines, Case Packers, Palletizers, etc.
• Shall be responsible for the maintenance, troubleshooting and upkeep of allied equipments like Blenders, mixers and batch vessels, Storage hoppers & silos, Feeders and Conveyors, Pulverizes, mixers, agitators and other ancillary parts, Valves, gates and airlocks, Dust collection and cleaning systems, Large Capacity Oil Storage tanks etc.
• Shall be proficient in handling Electrical Setup comprising of HT Lines, 33 KV Yard with GOD, 125 AMP drop out fuses, Large capacity OLTC transformers ( 1250 to 2500 KVA), CTPT, 33 KVA HT Panels with Air Circuit Breakers, PCC, MCC, 415 V VCC, APFC Panels, Large Capacity DG sets, High-Capacity Induction Motors etc, their maintenance, troubleshooting and upkeep.
• Shall plan and ensure execution of breakdown and preventive & predictive maintenance of various electrical equipments and utilities and thus ensure uninterrupted availability of equipments for production.
• Shall be responsible for Monitoring the Power and Steam Consumption and controlling the same through periodic review and energy reduction initiatives.
• Shall be responsible for the instrumentation setup of the plant, their sound functioning, calibration and performance comprising of PLC based SCADA system of Continuous Process Plants, Flow Meters, Mass Flow Meters, VFDs, Pneumatic Control Valves, Level Gauges, Weighing Systems comprising of hoppers, weighing scales, weighbridges etc
• Shall take care of the Civil maintenance of the plant like structural stability, Road maintenance, painting, repairs of buildings and other structures and their upkeep.
• Responsible for the maintenance budget and Inventory control of Consumables and Spares.
• Preparing Capex proposals for the replacement of old machinery / equipments, energy conservation measures, productivity improvement etc.
• Responsible for routine Capex projects like Capacity Expansion, New Product Introduction, Diversification of Product Portfolio, Energy Conservation and Energy Management Projects, Shop floor efficiency optimization projects, Automation Projects etc.
• Shall be responsible for Execution of the daily departmental activities / projects with Safety, Cost Budget and Agreed timelines.
• Shall manage and coordinate with all stakeholders like supplier, contractor, statutory & legal bodies and other departments to meet departmental goals and objectives.
• Liaisoning with local authorities like Boiler Inspectorate, Gas Authority of India Ltd, Electricity Board, etc. related to the departmental work.
• Shall manage a host of Contractors related to fabrication and maintenance, project activities, Contactor Safety Management, and oversee necessary documentation & reporting.
• Shall comply to the requirements of ISO, GMP, TPM & TQM systems in the Department.

Who are we looking for

Education and Experience:

• Qualification: B.E in Mech. or equivalent from reputed institutes.
• Desirable: Energy Management Qualification is desirable.
• Experience: Around 15 to 18 years experience in senior position like Plant Engineering Head with hands-on experience in managing overall engineering department of a large FMCG manufacturing facility.
• Experience in Maintenance / Engineering of Continuous Process Plants, Chemical Plants with maintenance of Soap, Liquid, Gel and Paste manufacturing machineries / equipments and related utilities.
• Selection & Sizing of Process Utilities equipment
• Energy Reduction, IOT, Industry 4.0 related to Manufacturing Process & Utilities.

Key Skills:

• Should be proficient in handling a large engineering services team comprising of Mechanical, Electrical and Instrumentation Engineers, Technicians and Contractors.
• Maintenance budget planning, monitoring, and control.
• Excellent Engineering / Technical, Maintenance and Troubleshooting skills.
• Sound knowledge of Construction Standards, NBC Codes, IBR codes, ASTM / ASME & IS standards.
• Costing of Utilities Steam, Gas, Electricity, Compressed air, refrigeration & chilling etc.
• Good interpersonal & communication skills managing internal & external stakeholders.
• Ability to work under critical situations and handle multiple tasks through a complex team.
• Proficient in use of MS Office especially Word, Excel and SAP etc.