Maintenance Executive ( Pharma Division )

Dharampal Satyapal Group (DS Group); Dadri; On-site; INR 600,000 - 800,000; Full time

Job summary

DS Group in India is seeking a skilled Maintenance Engineer to oversee machine and utility systems, ensuring high availability and reliability. You will lead preventive, predictive, and breakdown maintenance, troubleshoot mechanical and electrical issues, and coordinate with production for minimal downtime.

You will implement maintenance plans, maintain records, and drive continuous improvement through TPM and Kaizen initiatives, ensuring safety compliance and efficient energy use.

Qualifications

• Candidates should have hands-on experience in preventive, predictive and breakdown maintenance.
• Ability to troubleshoot mechanical, electrical, pneumatic, hydraulic, and control-related issues.
• Experience with maintenance planning, scheduling, and documentation.

Responsibilities

• Carry out preventive, predictive, and breakdown maintenance of production machinery and equipment.
• Troubleshoot mechanical, electrical, pneumatic, hydraulic, and control-related issues.
• Maintain machine availability, reliability, and performance.
• Attend breakdowns promptly and minimize downtime and losses.
• Support installation, commissioning, modification, and relocation of machinery.
• Coordinate with production to plan maintenance without impacting schedules.
• Maintain maintenance records, checklists, and equipment history.
• Identify energy conservation opportunities and optimize utility consumption.
• Coordinate with vendors, OEMs and service providers for maintenance work.
• Drive continuous improvement through Kaizen, TPM, RCA, and 5S.

Skills

Preventive maintenance

Predictive maintenance

Troubleshooting

Mechanical knowledge

Electrical & controls

Lubrication & calibration

Team coordination

Education

Diploma / Degree in Mechanical/Electrical Engineering

Job description

1. Machine & Equipment Maintenance

• Carry out preventive, predictive, and breakdown maintenance of production machinery and associated equipment.
• Troubleshoot and rectify mechanical, electrical, pneumatic, hydraulic, and control-related issues as applicable.
• Ensure machines are maintained to achieve maximum availability, reliability, and performance.
• Conduct regular inspection of machines to identify abnormal conditions, wear and tear, leaks, vibration, overheating, and other potential failures.
• Attend machine breakdowns promptly and minimize equipment downtime and production losses.
• Ensure proper lubrication, alignment, tightening, calibration, and replacement of machine components as per maintenance schedules.
• Support installation, commissioning, modification, and relocation of machinery and equipment.
• Coordinate with production teams to plan maintenance activities without affecting production schedules wherever possible.

2. Utility Maintenance

• Operate, monitor, and maintain critical plant utility systems such as:
• Air compressors and compressed-air systems
• DG sets and power backup systems
• HVAC / air-conditioning systems
• Chillers and cooling towers
• Pumps and water systems
• Boilers and steam systems, where applicable
• RO / ETP / STP systems, where applicable
• Electrical distribution and panels
• Fire-fighting and other essential utility systems
• Monitor utility parameters and ensure continuous availability of utilities to support production.
• Identify abnormal consumption, leakages, equipment inefficiencies, and opportunities for energy conservation.
• Maintain utility equipment in accordance with OEM recommendations and statutory requirements.

3. Preventive & Predictive Maintenance

• Prepare and execute daily, weekly, monthly, and annual preventive maintenance plans.
• Maintain maintenance checklists, inspection schedules, and equipment history.
• Analyze recurring failures and implement root-cause corrective actions.
• Monitor equipment health through condition-monitoring techniques such as vibration, temperature, current, pressure, and other relevant parameters.
• Recommend replacement or refurbishment of equipment/components based on condition and life-cycle considerations.

4. Breakdown & Troubleshooting

• Respond quickly to emergency equipment breakdowns.
• Diagnose faults systematically and restore equipment to normal operating condition.
• Record breakdown details, downtime, root cause, corrective action, and spares used.
• Identify recurring breakdowns and develop permanent corrective measures.
• Coordinate with OEMs, service engineers, contractors, and vendors for complex technical issues.

5. Maintenance Planning & Documentation

• Maintain accurate records of:
• Preventive maintenance
• Breakdown maintenance
• Equipment history
• Spare parts consumption
• Utility consumption
• Maintenance activities and observations
• Maintain equipment-wise maintenance schedules and checklists.
• Prepare reports on breakdown frequency, downtime, MTBF, MTTR, maintenance costs, and equipment availability.
• Ensure maintenance documentation is updated and readily available for audits.

6. Spare Parts & Inventory Management

• Identify critical spare parts and maintain adequate inventory levels.
• Prepare spare-parts requirements based on equipment criticality and maintenance plans.
• Coordinate with stores and purchase teams for timely availability of maintenance spares.
• Ensure proper storage and identification of critical spares, tools, and consumables.
• Monitor spare consumption and identify opportunities to reduce maintenance costs.

7. Safety & Compliance

• Ensure all maintenance activities are carried out in accordance with safety procedures and statutory requirements.
• Follow and enforce LOTO (Lockout/Tagout) and safe isolation procedures wherever applicable.
• Ensure proper use of PPE, tools, and safety equipment during maintenance activities.
• Support safety inspections, risk assessments, and maintenance-related audits.
• Ensure machines and utilities are operated and maintained within defined safety limits.
• Coordinate with EHS teams to close maintenance-related safety observations.

8. Vendor & Contractor Management

• Coordinate with external contractors, OEMs, and service providers for maintenance, servicing, and equipment-related activities.
• Supervise contractor work to ensure quality, safety, and timely completion.
• Evaluate service requirements and support vendor negotiations/technical evaluations where required.
• Verify service reports and ensure proper closure of maintenance jobs.

9. Continuous Improvement

• Identify opportunities to improve machine reliability, productivity, energy efficiency, and maintenance effectiveness.
• Participate in Kaizen, TPM, 5S, RCA, and other continuous improvement initiatives.
• Implement measures to reduce breakdowns, downtime, energy consumption, and maintenance costs.
• Suggest equipment modifications and engineering improvements to improve machine performance and safety.

10. Team Coordination

• Coordinate closely with Production, Quality, EHS, Stores, Purchase, and Engineering teams.
• Provide technical support to operators for basic machine troubleshooting and autonomous maintenance.
• Guide maintenance technicians/helpers in carrying out maintenance activities safely and effectively.
• Ensure proper handover of pending maintenance activities between shifts.

Key Performance Indicators (KPIs)

• Machine and equipment availability
• Breakdown frequency and downtime
• MTBF Mean Time Between Failures
• MTTR – Mean Time To Repair
• Preventive maintenance compliance
• Utility availability and reliability
• Energy consumption and cost optimization
• Maintenance cost per unit/production output
• Spare-parts consumption and inventory control
• Repeat breakdown reduction
• Safety compliance and closure of maintenance-related observations