Maintenance Manager

DMart; Mumbai; Presencial; INR 2 500 000 - 4 200 000; Tempo integral

Resumo da oferta

DMart is seeking a senior maintenance leader to standardise and govern maintenance across India for repacking centres. You will drive reliability, preventive/predictive maintenance, and cost management while leading cross-site teams and coordinating with Operations and Procurement.

The role requires experience in multi-site maintenance, strong analytical skills, and a track record in TPM/Kaizen programs, with travel across India.

Qualificações

• Experience leading maintenance across multiple factories or packaging ops.
• Strong knowledge of preventive & predictive maintenance, TPM, and cost control.
• Hands-on experience with OEE, MTBF, MTTR.
• Proven ability to manage budgets, OEMs and vendors.
• Willingness to travel across India.
• Leadership of multi-site maintenance teams.

Responsabilidades

• Develop and implement pan-India maintenance strategy for repacking centres.
• Establish standard maintenance processes, SOPs and escalation mechanisms.
• Drive availability, reliability and uptime improvements across centres.
• Lead root-cause analysis for major breakdowns and implement corrective actions.
• Collaborate with Operations to align maintenance with production schedules.
• Establish spare-parts framework and inventory norms.
• Lead continuous improvement initiatives (Kaizen, TPM, TQM).
• Prepare and manage annual maintenance budgets and performance reviews.

Conhecimentos

Maintenance leadership

OEE improvement

MTBF/MTTR

Kaizen/TPM

Root-cause analysis

Team leadership

Ferramentas

Maintenance MIS

Descrição da oferta de emprego

Role & responsibilities

A. Pan-India Maintenance Strategy and Governance

• Develop and implement a standardised maintenance strategy for all repacking centres.
• Establish common maintenance processes, preventive maintenance schedules, inspection standards and equipment-wise maintenance protocols.
• Define maintenance organisation structures, manpower requirements, roles and responsibilities for each centre.
• Establish standard operating procedures, maintenance checklists, escalation mechanisms and performance review systems.
• Conduct periodic reviews of maintenance performance across centres and drive closure of identified gaps.
• Develop a maintenance capability roadmap aligned with business growth, new centre commissioning and capacity expansion.

B. Equipment Reliability and Downtime Reduction

• Drive improvement in equipment availability and reliability across all repacking centres.
• Establish standardised measurement and reporting of equipment-wise downtime, breakdown frequency, MTBF and MTTR.
• Review major and repetitive breakdowns and ensure structured root-cause analysis and permanent corrective actions.
• Identify chronic equipment failures and implement network-wide solutions to prevent recurrence.
• Benchmark equipment performance across centres and replicate successful reliability practices.
• Work with Operations to minimise production losses attributable to equipment breakdowns, speed losses and frequent stoppages.

C. Preventive and Predictive Maintenance Excellence

• Ensure implementation and adherence to preventive maintenance schedules across all centres.
• Establish systems to monitor maintenance compliance, overdue activities and repeat failures.
• Introduce condition-based and predictive maintenance practices wherever technically and commercially viable.
• Standardise lubrication practices, inspection routines, equipment servicing and maintenance history documentation.
• Drive equipment health assessments and prioritise maintenance interventions based on criticality and operational risk.
• Ensure planned maintenance is integrated with production schedules to minimise disruption to operations.

D. Spare-Parts Strategy and Inventory Optimisation

• Establish a Pan-India critical spare-parts framework based on equipment criticality, failure history, consumption and supplier lead times.
• Standardise spare-parts specifications across centres wherever technically feasible.
• Define inventory norms, minimum and maximum stock levels, replenishment mechanisms and emergency procurement protocols.
• Ensure availability of critical spares to prevent prolonged production downtime.
• Monitor spare-parts consumption, inventory ageing, stock-outs, obsolete inventory and emergency purchases.
• Work with Procurement, Stores and OEMs to improve sourcing efficiency, negotiate service arrangements and optimise spare-parts costs.
• Evaluate opportunities for common inventories, inter-centre transfers and centralised procurement.

E. Productivity, OEE and Process Efficiency

• Drive improvement in Overall Equipment Effectiveness (OEE), machinery throughput and equipment performance in partnership with Operations.
• Identify equipment-related constraints affecting repacking speed, line efficiency, output and capacity utilisation.
• Lead technical interventions to reduce minor stoppages, speed losses, changeover losses and recurring equipment-related wastage.
• Support equipment capability assessments and identify opportunities to improve machine utilisation and throughput.
• Evaluate and recommend equipment modifications, upgrades and reliability improvements based on operational benefits and payback.
• Track the impact of maintenance initiatives on productivity, output per shift and cost per tonne.

F. Kaizen, TPM and TQM

• Lead maintenance-related continuous improvement initiatives across all repacking centres.
• Establish structured Kaizen programmes focused on breakdown elimination, equipment reliability, productivity and cost reduction.
• Drive Total Productive Maintenance (TPM), 5S and relevant TQM practices in collaboration with Operations and Quality.
• Implement structured problem-solving methodologies, including 5 Why analysis, fishbone analysis and corrective/preventive action tracking.
• Promote operator-led basic equipment care, including cleaning, inspection and early identification of abnormalities.
• Identify and replicate best practices across centres and build a repository of proven technical improvements.
• Measure and report the financial and operational benefits delivered through maintenance-led improvements. Closely work with the COE to improve the efficacy.

G. Maintenance Cost and Budget Management

• Prepare and manage the annual maintenance budget across all repacking centres.
• Establish benchmarks for maintenance cost per tonne, cost per machine or line, spare-parts consumption and external servicing expenditure, as appropriate.
• Monitor centre-wise and network-wide maintenance expenditure against approved budgets.
• Drive optimisation of repair costs, spare consumption, service contracts and maintenance manpower productivity.
• Evaluate repair-versus-replacement decisions for ageing or unreliable equipment.
• Build business cases for major maintenance interventions, equipment upgrades and reliability investments.
• Ensure cost reduction initiatives do not compromise equipment reliability, food safety or workplace safety.

H. Technical Projects and New Centre Commissioning

• Provide maintenance inputs during the planning and selection of new repacking machinery and equipment.
• Coordinate with the Projects team during new centre development, expansion and capacity-enhancement projects.
• Define maintenance-readiness requirements for new equipment, including documentation, critical spares, servicing arrangements and maintenance access.
• Participate in equipment installation, commissioning, performance validation and operational handover.
• Ensure maintenance teams are trained before new machinery is handed over for regular production.
• Review equipment performance after commissioning and ensure closure of reliability and maintainability issues.
• Coordinate with central MEP and Civil teams on interfaces affecting machinery installation and maintenance, while keeping ownership of MEP and civil maintenance separate.

I. Team Leadership and Capability Development

• Lead, coach and develop unit-level maintenance managers and their teams across India.
• Establish competency requirements and structured technical training programmes for maintenance personnel.
• Develop standard skill matrices, training plans and assessments for critical equipment and maintenance practices.
• Build technical troubleshooting capabilities to reduce dependency on OEMs and external service providers where feasible.
• Review centre-wise manpower adequacy, shift coverage and technical capability.
• Establish performance goals and periodic reviews for maintenance managers based on reliability, downtime, preventive maintenance and cost outcomes.
• Promote a culture of accountability, root-cause resolution, safety and continuous improvement.

J. Safety, Food Safety and Compliance

• Ensure maintenance activities comply with applicable machinery safety requirements, isolation and lockout/tagout procedures.
• Ensure machine guards, interlocks and safety devices remain functional and are not bypassed.
• Drive compliance with food-safety and hygiene requirements during maintenance interventions in repacking areas.
• Establish standards for tool control, lubrication, maintenance materials and prevention of foreign-body contamination.
• Ensure timely closure of maintenance-related audit findings, safety observations and recurring non-conformities.
• Coordinate with Quality, Safety and the relevant MEP/Civil teams on cross-functional compliance requirements.

K. Maintenance MIS and Performance Reviews

• Develop a common Pan-India maintenance dashboard with centre-wise and consolidated performance indicators.
• Establish daily or shift-level breakdown reporting at unit level and periodic performance reviews at regional and national levels.
• Conduct monthly maintenance performance reviews with unit maintenance managers and relevant Operations leaders.
• Benchmark centre performance and identify underperforming equipment, recurring failures and opportunities for intervention.
• Track action plans, accountability and completion timelines for major maintenance improvement initiatives.
• Present periodic performance updates, risks and investment requirements to business leadership.

Preferred candidate profile

• Experience leading maintenance across multiple factories, plants, warehouses with production operations or packaging facilities.
• Experience in industrial maintenance, manufacturing, food processing, FMCG or packaging operations, with demonstrated multi-site responsibility.
• Strong knowledge of preventive and predictive maintenance, equipment reliability, breakdown analysis, critical spare-parts management and maintenance planning.
• Practical experience with OEE, MTBF, MTTR, TPM, TQM, Kaizen and structured problem-solving.
• Experience managing maintenance budgets, technical teams, OEMs, vendors and equipment-related capital projects.
• Strong analytical capability, leadership skills, stakeholder management and willingness to travel across India.