Head Mechanical Maintenance

Karamtara Engineering Pvt. Ltd.; Nagpur District; On-site; INR 2,800,000 - 4,200,000; Full time

Job summary

Karamtara Engineering Pvt. Ltd. in Nagpur, Maharashtra, seeks a Head of Mechanical Maintenance to lead the Fasteners Division’s maintenance functions.

You will develop preventive, predictive, and breakdown maintenance programs, drive reliability improvements, and manage a multi-disciplinary team of engineers, supervisors, fitters and technicians.

The role emphasizes MTBF/MTTR metrics, TPM, 5S and continuous improvement, with the aim of minimizing downtime and optimizing maintenance costs.

Qualifications

• B.E./B.Tech./Diploma in Mechanical Engineering.
• 12–18 years total experience in mechanical maintenance.
• Management/leadership experience preferred.

Responsibilities

• Lead the complete mechanical maintenance function for the Fasteners Division.
• Plan and monitor preventive, predictive and breakdown maintenance activities.
• Develop annual, monthly and weekly maintenance plans.

Skills

Maintenance leadership

Troubleshooting

Root Cause Analysis

Maintenance planning

Kaizen

OEE improvement

Vendor management

Education

B.E./B.Tech./Diploma – Mechanical Engineering

Tools

CMMS/ERP

Job description

Greetings!

Role & responsibilities

HEAD - MECHANICAL MAINTENANCE

Position: Head Mechanical Maintenance

Division: Fasteners

Location: Butibori, Nagpur, Maharashtra

Department: Mechanical Maintenance

Reporting To: Plant Head / Business Head

Education: B.E./B.Tech./Diploma – Mechanical Engineering

1. JOB PURPOSE

To lead the complete Mechanical Maintenance function of the Fasteners Division and ensure high equipment availability, minimum breakdowns, optimum maintenance cost and uninterrupted production.

The position will be responsible for developing and implementing preventive, predictive and breakdown maintenance systems for fastener manufacturing equipment, improving equipment reliability and leading the mechanical maintenance team.

2. KEY RESPONSIBILITIES

A. Mechanical Maintenance Leadership

• Lead the complete mechanical maintenance function for the Fasteners Division.
• Ensure maximum availability and reliability of production equipment.
• Plan and monitor preventive, predictive and breakdown maintenance activities.
• Develop annual, monthly and weekly maintenance plans.
• Monitor maintenance performance through MTBF, MTTR, machine availability and breakdown hours.
• Establish robust maintenance systems to minimize unplanned downtime.

B. Fastener Manufacturing Equipment Maintenance

Ensure maintenance and reliability of equipment such as:

• Cold heading / cold forging machines
• Hot forging machines
• Bolt-making machines
• Nut-forming machines
• Thread rolling machines
• Nut tapping machines
• Tapping machines
• Wire drawing equipment
• Presses and power presses
• Heat treatment equipment
• Shot blasting machines
• Grinding machines
• Washing / cleaning equipment
• Compressors, pumps and other mechanical utilities
• Material handling equipment and associated mechanical systems

C. Breakdown Maintenance & Troubleshooting

• Lead major mechanical breakdowns and ensure quick restoration of equipment.
• Identify root causes of recurring failures.
• Conduct RCA using 5-Why, Fishbone and other problem-solving techniques.
• Implement permanent corrective and preventive actions.
• Reduce repeat breakdowns and improve equipment reliability.
• Maintain detailed breakdown history and failure analysis.

D. Preventive & Predictive Maintenance

• Implement equipment-wise preventive maintenance schedules.
• Ensure timely inspection and replacement of critical components.
• Monitor condition of bearings, gears, shafts, couplings, chains, belts, hydraulic/pneumatic systems and lubrication systems.
• Introduce condition-based and predictive maintenance wherever applicable.
• Ensure proper lubrication management.
• Plan periodic overhauling of critical machines.

E. Maintenance Planning & Shutdown

• Prepare planned shutdown and annual maintenance schedules.
• Coordinate shutdown activities with Production, Quality, Stores and other departments.
• Ensure timely completion of shutdown jobs.
• Review post-shutdown machine performance.
• Minimize production loss during planned maintenance.

F. Spare Parts & Cost Control

• Identify critical mechanical spare parts and maintain adequate inventory.
• Develop minimum/maximum stock levels for critical spares.
• Coordinate with Purchase and Stores for timely procurement.
• Control maintenance expenditure through effective planning.
• Identify opportunities for spare localization, refurbishment and cost reduction.
• Ensure optimum utilization of maintenance resources.

G. Team Management

• Lead Mechanical Maintenance Managers/Engineers, Supervisors, Fitters and Technicians.
• Plan manpower deployment across shifts.
• Develop technical skills of maintenance personnel.
• Conduct training on troubleshooting, preventive maintenance and safe maintenance practices.
• Build a technically strong and responsive maintenance team.
• Set KPIs and monitor individual/team performance.

H. Machine Improvement & Reliability

• Identify chronic machine problems and drive reliability improvement projects.
• Implement machine modifications and engineering improvements.
• Improve machine OEE through reduction of breakdown and minor stoppage losses.
• Support automation and technology-upgradation projects.
• Work with OEMs for machine improvement and technical support.
• Participate in new machine installation and commissioning.

I. Safety & Compliance

• Ensure compliance with all maintenance safety procedures.
• Implement LOTO practices during maintenance activities.
• Ensure safe working practices during breakdowns and shutdowns.
• Conduct maintenance-related safety audits and corrective actions.
• Support compliance with applicable ISO 9001, ISO 14001 and ISO 45001 systems.

3. KEY PERFORMANCE INDICATORS

• Mechanical Machine Availability
• MTBF improvement
• MTTR reduction
• Breakdown Hours Reduction
• Preventive Maintenance Compliance
• Repeat Breakdown Reduction
• OEE Improvement
• Maintenance Cost per Ton
• Critical Spare Availability
• Shutdown Maintenance Effectiveness
• Zero major maintenance-related safety incidents

Preferred candidate profile

4. REQUIRED TECHNICAL SKILLS

• Strong knowledge of mechanical maintenance of forging and fastener manufacturing equipment.
• Hands-on knowledge of cold/hot forging machines.
• Strong understanding of hydraulic and pneumatic systems.
• Knowledge of bearings, gears, shafts, couplings, lubrication and power transmission.
• Knowledge of preventive and predictive maintenance.
• Strong troubleshooting and RCA skills.
• Knowledge of TPM, 5S, Kaizen and Continuous Improvement.
• Knowledge of maintenance planning and shutdown management.
• Familiarity with CMMS/ERP-based maintenance systems.
• Strong vendor/OEM management skills.

5. EXPERIENCE

• 12–18 years of total experience in mechanical maintenance.
• Minimum 4–6 years in a managerial/leadership position.
• Strong preference for candidates from:
• Fasteners
• Cold Forging
• Hot Forging
• Auto Components
• Engineering Manufacturing
• Heavy Engineering

6. DESIRED CANDIDATE PROFILE

The ideal candidate should be a hands-on Mechanical Maintenance Leader with strong experience in forging/fastener manufacturing equipment. The candidate should be capable of independently managing maintenance operations, leading a multi-level maintenance team, reducing machine breakdowns, improving MTBF/MTTR and supporting production and OEE targets.

7. KEY COMPETENCIES

• Leadership & Team Management
• Mechanical Troubleshooting
• Equipment Reliability
• Root Cause Analysis
• Preventive & Predictive Maintenance
• Cost Control
• Shutdown Planning
• Spare Parts Management
• Continuous Improvement
• Cross-functional Coordination
• Safety Leadership
• Decision Making