Maintenance Manager

Cummins; Pune District; On-site; INR 2,600,000 - 3,800,000; Full time

Job summary

Cummins in Pune seeks a Senior Plant Engineer to lead end-to-end plant engineering and maintenance across machining, engine assembly and test beds. You will ensure high uptime, reliability, safety and cost efficiency while coordinating 350+ machines, 100 staff and 70 contract workers.

You will drive TPM, predictive maintenance, Industry 4.0 initiatives, CAPEX projects, and energy efficiency, with focus on compliance to IATF 16949 and ISO standards, and continuous improvement of maintenance

Qualifications

• Experience leading maintenance for 350+ machines in machining and engine plants.
• Proven skills in TPM, RCA and predictive maintenance.
• CAPEX/OPEX budgeting and project execution knowledge.
• Knowledge of IATF 16949 and ISO 45001/14001/50001 standards.
• Strong shop-floor leadership for 24x7 operations.

Responsibilities

• Lead mechanical, electrical and electronics maintenance for 350+ machines across Machining and ATPU.
• Drive preventive, predictive and condition-based maintenance, TPM, RCA and zero-breakdown culture.
• Own equipment performance: OEE, uptime, MTBF, MTTR and breakdown reduction.
• Manage facility and utilities including HT electrical systems, HVAC, compressors, DG, cranes, PIVs and civil infrastructure.
• Lead Greenfield/Brownfield projects, CAPEX, new equipment installation, commissioning and plant upgrades.
• Drive Industry 4.0, MES, digital maintenance and predictive analytics initiatives.
• Manage spares, vendors, maintenance budgets and cost optimization.
• Lead approximately 100 employees + 70 contract workforce across a 3-shift operation.
• Ensure compliance with safety, environmental and statutory requirements including Factory Inspector, Electrical Inspector, PESO and MPCB.
• Drive energy-efficiency initiatives and continuous improvement.

Skills

Diesel Engine / Powertrain

Machining & Engine Assembly

CNC/VMC/SPM

Vibration analysis

Thermography

CAPEX/OPEX management

Large maintenance teams leadership

Engineering maintenance planning

Shop-floor leadership

Safety & 24x7 mindset

Education

B.E./B.Tech – Mechanical / Electrical / Electronics

Tools

SAP PM

Maximo

Job description

Job Summary

Lead end-to-end Plant Engineering & Maintenance across Machining, Engine Assembly & Test Beds, Utilities and Facilities, ensuring high uptime, reliability, safety, compliance and cost efficiency

Key Responsibilities

• Lead Mechanical, Electrical & Electronics Maintenance for 350+ machines/equipment across Machining and ATPU.
• Drive preventive, predictive and condition-based maintenance, TPM, RCA and zero-breakdown culture.
• Own equipment performance: OEE, uptime, MTBF, MTTR and breakdown reduction.
• Manage facility and utilities including HT electrical systems, HVAC, compressors, DG, cranes, PIVs and civil infrastructure.
• Lead Greenfield/Brownfield projects, CAPEX, new equipment installation, commissioning and plant upgrades.
• Drive Industry 4.0, MES, digital maintenance and predictive analytics initiatives.
• Manage spares, vendors, maintenance budgets and cost optimization.
• Lead approximately 100 employees + 70 contract workforce across a 3-shift operation.
• Ensure compliance with safety, environmental and statutory requirements including Factory Inspector, Electrical Inspector, PESO and MPCB.
• Drive energy-efficiency initiatives and continuous improvement.

Competencies

Collaborates - Building partnerships and working collaboratively with others to meet shared objectives.
Communicates effectively - Developing and delivering multi-mode communications that convey a clear understanding of the unique needs of different audiences.
Develops talent - Developing people to meet both their career goals and the organization’s goals.
Drives engagement - Creating a climate where people are motivated to do their best to help the organization achieve its objectives.
Health and Safety Fundamentals - Champions and models proactive health and safety behaviors by identifying, reporting and participating in actions to improve health and safety in order to build an interdependent culture and contribute to an injury-free workplace.
Data Mining - Extracts insights from data by identifying relationships and patterns through use of a suite of data exploration and data visualization techniques to understand the underlying structure of the data and enable sound conclusions upon model building.
Equipment/Capital Procurement - Selects manufacturing equipment which meets the Cummins manufacturing specifications and meets the project or program needs.
Manufacturing Prognostics - Applies prognostics techniques by collecting real time equipment conditions and then use advanced analytics and artificial intelligence technologies to project future failures to eliminate unplanned equipment and systems down time.
Project Management - Establishes and maintains the balance of scope, schedule and resources for a temporary effort (a "project"). Ensures results/impact from temporary effort are fully realized as possible.
Values differences - Recognizing the value that different perspectives and cultures bring to an organization.
Plans and aligns - Planning and prioritizing work to meet commitments aligned with organizational goals.
Preventative and Predictive Maintenance - Interprets machine and tool maintenance records and data to develop and execute preventative and predictive management strategies to drive continuous improvement within the manufacturing process.
Balances stakeholders - Anticipating and balancing the needs of multiple stakeholders.
Builds effective teams - Building strong-identity teams that apply their diverse skills and perspectives to achieve common goals.

Education, Licenses, Certifications

B.E./B.Tech – Mechanical / Electrical / Electronics

This position may require licensing for compliance with export controls or sanctions regulations.

Experience

18–22 years of plant engineering / maintenance experience

• Strong exposure to Diesel Engine / Powertrain / Automotive manufacturing.
• Hands-on experience in Machining + Engine Assembly + Test/Dyno.
• Strong knowledge of CNC/VMC/SPM, TPM, SAP PM/Maximo, vibration analysis and thermography.
• Experience with CAPEX/OPEX, facility management and large maintenance teams.
• Knowledge of IATF 16949, ISO 45001/14001/50001 and statutory compliance.
• Strong shop-floor orientation with a 24x7 manufacturing mindset.

Key Deliverables

• High equipment uptime and plant reliability.
• Reduction in breakdowns and maintenance costs.
• Effective execution of CAPEX and strategic projects.
• Improved maintenance process maturity and stakeholder satisfaction.
• Optimized spare parts inventory and manufacturing overhead management.
• Safe, compliant, and efficient facility operations.

Cummins is an equal opportunity employer. Our policy is to provide equal employment opportunities to all qualified persons without regard to race, sex, color, disability, national origin, age, religion, union affiliation, sexual orientation, veteran status, citizenship, gender identity, or other status protected by law.