Lead - Plant Maintenance

Lenskart; Hyderabad; On-site; INR 1,800,000 - 3,200,000; Full time

Benefits offered by this job

Health insurance

Job summary

Lenskart India is seeking a seasoned Maintenance Leader to develop and execute the plant maintenance strategy, maximizing equipment availability and efficiency across a highly automated manufacturing environment. You will drive preventive, predictive and RCm programs, establish KPIs, lead RCA and CAPA, and monitor MTBF/MTTR to continuously improve asset life and uptime.

Additionally, you will manage budgets, spare parts and vendor contracts, and collaborate with Production, Quality, Engineering,

Qualifications

• 10+ years of experience in maintenance, engineering or plant operations.
• Experience leading a large team including Maintenance Managers, Engineers and Technicians.
• Strong exposure to automation, Industry 4.0, condition monitoring, IoT and data‑driven maintenance.
• Strong CAPEX planning, installation, commissioning and ramp‑up of new machines/production lines.
• Hands‑on, agile and comfortable in a fast‑paced manufacturing environment with high ownership.

Responsibilities

• Develop and execute the plant maintenance strategy to maximize equipment availability, reliability, and operational efficiency.
• Drive preventive, predictive, and reliability‑centered maintenance (RCM) programs to minimize breakdowns.
• Establish maintenance KPIs and continuously improve equipment performance and asset life.
• Lead maintenance activities for production machinery, automation systems, utilities, and facility infrastructure.
• Ensure rapid response to equipment failures to minimize production downtime.
• Lead Root Cause Analysis (RCA) and implement permanent CAPA.
• Monitor MTBF and MTTR to improve equipment reliability.
• Collaborate with cross‑functional teams to drive TPM, Lean, Six Sigma, digitalization and energy‑saving initiatives.

Skills

10+ years experience

Team leadership

Automation / Industry 4.0

CAPEX planning

Hands-on / ownership

Job description

Preferred candidate profile

• 10+ years of experience in maintenance, engineering, or plant operations, preferably in a highly automated manufacturing environment.
• Experience of handling a large team including Maintenance Managers, Engineers and Technicians
• Strong exposure to automation, Industry 4.0, condition monitoring, IoT and data-driven maintenance practices
• Strong experience in CAPEX planning, installation, commissioning and ramp-up of new machines/production lines
• Should be hands‑on, agile and comfortable working in a fast‑paced manufacturing environment with high ownership and accountability

Role & responsibilities

1. Maintenance Strategy & Asset Reliability

• Develop and execute the plant maintenance strategy to maximize equipment availability, reliability, and operational efficiency.
• Drive preventive, predictive, and reliability‑centered maintenance (RCM) programs to minimize breakdowns.
• Establish maintenance KPIs and continuously improve equipment performance and asset life.

2. Equipment & Facility Maintenance

• Lead maintenance activities for production machinery, automation systems, utilities, and facility infrastructure.
• Ensure timely maintenance of mechanical, electrical, pneumatic, hydraulic, PLC, robotics, HVAC, compressors, DG sets, and other critical plant equipment.
• Ensure rapid response to equipment failures to minimize production downtime.
• Lead Root Cause Analysis (RCA) and implement permanent corrective and preventive actions (CAPA).
• Monitor Mean Time Between Failures (MTBF) and Mean Time to Repair (MTTR) to improve equipment reliability.

3. Planning & Continuous Improvement

• Develop annual maintenance plans, shutdown schedules, and preventive maintenance calendars.
• Drive Total Productive Maintenance (TPM), Lean Manufacturing, and Six Sigma initiatives to enhance operational excellence.
• Identify and implement automation, digitalization, and energy‑saving opportunities.

4. Budget & Cost Management

• Prepare and manage the maintenance budget while ensuring cost‑effective operations.
• Optimize maintenance costs through effective planning, inventory control, and vendor management.
• Improve spare parts availability while minimizing inventory carrying costs.

5. Vendor & Contractor Management

• Manage relationships with OEMs, contractors, and service providers.
• Evaluate vendor performance and ensure timely execution of Annual Maintenance Contracts (AMCs).
• Ensure contractors comply with plant safety and quality standards.

6. Safety, Compliance & Risk Management

• Ensure all maintenance activities comply with statutory regulations, environmental norms, and company safety standards.
• Drive safe maintenance practices through Permit‑to‑Work (PTW), risk assessments, and hazard identification.
• Lead maintenance audits and ensure compliance with ISO, EHS, and regulatory requirements.

7. Cross‑Functional Collaboration

• Partner with Production, Quality, Engineering, Supply Chain, and EHS teams to achieve plant performance objectives.
• Support new equipment installation, commissioning, validation, and process improvement projects.
• Participate in capacity expansion and new technology implementation initiatives.

8. Performance Management

• Monitor and improve key maintenance metrics including:
• Equipment Uptime
• Overall Equipment Effectiveness (OEE)
• MTBF & MTTR
• Preventive Maintenance Compliance
• Maintenance Cost per Unit
• Spare Parts Inventory Accuracy
• Energy Consumption
• Safety Performance