Maintenance Head

MTC Business; Chennai; On-site; INR 1,200,000 - 1,600,000; Full time

Job summary

MTC Business in Chennai, India, is seeking a seasoned Maintenance & Reliability Manager to lead PM/PdM programs for heavy rotating machinery and downstream shredder lines.

You will manage a multi-disciplinary team, drive RCFA, optimize spares, and ensure safety and statutory compliance. The role emphasizes KPI tracking (MTTR, MTBF, OEE) and budget control to maximize plant uptime and reliability.

Responsibilities

• Develop and execute a comprehensive Preventive Maintenance (PM) and Predictive Maintenance (PdM) schedule to ensure equipment availability meets production targets.
• Implement condition-monitoring strategies, including vibration analysis, thermal imaging, oil/lubrication analysis, and acoustic monitoring on heavy rotating machinery.
• Establish root-cause failure analysis (RCFA) protocols using 5-Why, Fishbone, or FMEA methodologies following any critical breakdown, driving corrective actions to prevent recurrence.
• Track, evaluate, and report maintenance KPIs: Mean Time to Repair (MTTR), Mean Time Between Failures (MTBF), OEE, and scheduled compliance rates.

Job description

Key Responsibilities

1. Strategic Reliability & Maintenance Execution

• Develop and execute a comprehensive Preventive Maintenance (PM) and Predictive Maintenance (PdM) schedule to ensure equipment availability meets production targets.
• Implement condition-monitoring strategies, including vibration analysis, thermal imaging, oil/lubrication analysis, and acoustic monitoring on heavy rotating machinery.
• Establish root-cause failure analysis (RCFA) protocols using 5-Why, Fishbone, or FMEA methodologies following any critical breakdown, driving corrective actions to prevent recurrence.
• Track, evaluate, and report maintenance KPIs: Mean Time to Repair (MTTR), Mean Time Between Failures (MTBF), OEE, and scheduled compliance rates.

2. Plant Machinery & Heavy Asset Upkeep

• Size Reduction & Shearing Assets: Oversee wear management and rebuilds for heavy-duty metal shredders (rotors, hammers, wear plates, anvils, and reject gates) and hydraulic guillotine shears/balers.
• Separation & Sorting Lines: Maintain downstream non-ferrous and Automotive Shredder Residue (ASR) separation units, including magnetic drum separators, eddy current separators (ECS), induction sorters, air classifiers, and vibratory feeders.
• Heavy Hydraulics & Pneumatics: Direct troubleshooting and rebuilds of high-pressure hydraulic power units (HPUs), valves, hydraulic cylinders, heat exchangers, and filtration circuits.
• Material Handling & Yard Equipment: Supervise structural inspections, rope/chain maintenance, and scheduled overhauls for EOT scrap-handling cranes, heavy excavators, hydraulic mobile handlers, and weighbridge systems.

3. Inventory, Spares & Procurement Management

• Formulate and control the annual Maintenance Operating Budget (Opex) and Capital Expenditure (Capex) for plant upgrades, rebuilds, and structural overhauls.
• Establish a critical spares matrix and maintain optimal inventory levels for rapid-wear components (hammers, cutter blades, liner plates, heavy bearings, hydraulic seals, and spare motors) to prevent stockout-induced downtime.
• Standardize equipment parts and create technical specifications for purchasing high-wear metallurgical castings, mechanical drives, and fluid power components.
• Evaluate, negotiate, and manage Annual Maintenance Contracts (AMCs), external machine shops, re-chroming/grinding services, and third-party diagnostic vendors.

4. Safety, Statutory Compliance & Housekeeping

• Champion industrial safety practices, including Lockout/Tagout (LOTO), confined space entry, hot work permits, and line-break procedures during all maintenance activities.
• Ensure all pressure vessels, lifting tackles, EOT cranes, weighbridges, and electrical installations strictly adhere to local statutory inspections, factory acts, and regulatory standards.
• Implement 5S methodology and safe material staging within the central workshop, oil/lubricant storage rooms, and scrap maintenance bays.
• Drive fire protection readiness across hydraulic power rooms, shredder enclosure fire-suppression systems, and substation battery backup rooms.

5. Team Leadership & Contractor Supervision

• Lead, mentor, and upskill a multi-disciplinary team of mechanical & electrical engineers, fitters, certified welders, and technicians.
• Conduct regular shift briefings, technical tool-box talks, and skill gap analyses to continuously enhance in-house troubleshooting capabilities.
• Supervise external contractors and fabrication teams during major overhauls, relining outages, or structural retrofits, ensuring adherence to quality and safety standards.