Maintenance Shift In-charge (Mechanical, Electrical & Instrumentation)

Radical Bio Organics Limited; Tandur; On-site; INR 900,000 - 1,200,000; Full time

Job summary

Radical Bio Organics Limited in Telangana is seeking a Maintenance Shift In-charge to oversee MEI systems during rotational shifts. You will lead mechanical, electrical, and instrumentation maintenance, troubleshoot breakdowns, execute preventive tasks, and ensure proper shift handovers.

Experience in process plants, strong documentation and ERP/CMMS familiarity are required. The role demands strict safety practices, PTW/LOTO compliance, and supervision of technicians and contract crews.

Qualifications

• Diploma or B.E./B.Tech in Mechanical, Electrical, or Instrumentation & Control Engineering.
• 4–9 years of hands-on maintenance in continuous process plants with independent shift experience.
• Strong ability to read P&IDs, GA drawings, electrical schematics and loop diagrams.
• Proficient with ERP/CMMS systems and standard office tools.

Responsibilities

• Lead first-line MEI maintenance during shifts to minimize MTTR.
• Oversee troubleshooting and preventive maintenance for pumps, motors, switchgear, VFDs and instrumentation.
• Ensure accurate shift logs, MWOs, RCA reports and PM compliance.
• Maintain PTW/LOTO compliance and lead shift handovers with clear status updates.
• Supervise technicians, fitters, electricians, instrumentation techs and contract crews.

Skills

Multidisciplinary troubleshooting

Reading P&IDs & schematics

Documentation & ERP reporting

Education

Diploma or B.E./B.Tech in Mechanical, Electrical, or Instrumentation & Control Engineering

Tools

SAP PM

ERP Next

Maximo

Job description

Job Posting: Maintenance Shift In-charge (Mechanical, Electrical & Instrumentation)

Department: Plant Engineering & Maintenance

Reports To: Maintenance Manager

Supervises: Shift Technicians, Fitters, Electricians, Instrument Technicians, and Contract Maintenance Crews

Work Schedule: Rotational Shifts (General / A / B / C shifts, including weekend coverage as rostered)

Position Overview

We are seeking a proactive, technically well-rounded Maintenance Shift In-charge to oversee multidisciplinary plant maintenance across Mechanical, Electrical, and Instrumentation (MEI) systems during operational shifts.

This role serves as the frontline technical lead during running shifts, responsible for rapid breakdown troubleshooting, ongoing preventive maintenance execution, and seamless shift-to-shift technical handovers. In addition to field troubleshooting, the role requires meticulous documentation disciplinemanaging daily logbooks, work orders, breakdown root-cause reports, Permit-to-Work (PTW/LOTO) records, calibration logs, and ERP/CMMS maintenance updates.

Key Responsibilities

1. Mechanical Maintenance & Field Troubleshooting

• Lead first-line response to mechanical failures during the shift to minimize mean time to repair (MTTR) across rotating and static equipment.
• Troubleshoot and service centrifugal/screw/positive displacement pumps, mechanical seals, gearboxes, blowers, agitators, screw conveyors, bucket elevators, valves, and piping networks.
• Supervise pump and motor shaft alignments (dial indicator/laser), dynamic balancing checks, bearing replacements, and gland packing adjustments.
• Conduct regular shift condition-monitoring rounds: check vibration levels, surface temperatures, bearing house lube levels, oil contamination, and unusual operating noises.

2. Electrical Maintenance & Power Distribution

• Attend to shift-level electrical faults across HT/LT switchgear, motor control centers (MCC), power control centers (PCC), variable frequency drives (VFDs), and soft starters.
• Perform emergency motor checks: insulation resistance tests (Megger), winding resistance measurements, phase current balance checks, and thermal overload relay investigations.
• Supervise maintenance of emergency diesel generators (DG sets), uninterrupted power supply (UPS) banks, plant illumination, and battery chargers during power dips or islanding events.
• Coordinate breaker rack-in/rack-out operations, fuse replacements, and transformer inspection checks (oil level, silica gel color, winding/oil temperature indicators).

3. Instrumentation & Automation Support

• Diagnose and rectify field instrumentation faults involving 4–20 mA loop circuits, RTDs, thermocouples, pressure transmitters, level transmitters (radar/differential pressure), and flow meters (electromagnetic/mass flow).
• Troubleshoot pneumatic control valves, positioners (smart/analog), solenoid valves (SOVs), air regulators, and actuator diaphragm leaks.
• Assist DCS/PLC shift operators in resolving communication drops, I/O card channel faults, interlock bypass verifications, and field sensor drift.
• Carry out zero/span calibrations and basic field loop checks when process anomalies occur during running shifts.

4. Maintenance Documentation & ERP Management

• Maintain comprehensive, error-free Daily Shift Maintenance Logs, documenting every breakdown, equipment stoppage, root cause identified, parts replaced, and pending punch points.
• Generate and close out Maintenance Work Orders (MWOs) in the plant CMMS/ERP system, logging labor hours, spare parts consumed, and failure codes.
• Prepare initial Incident & Breakdown Reports with immediate root cause analysis (RCA) and 5-Why problem-solving for all trips lasting longer than 15 minutes.
• Maintain calibration records, motor test records, safety valve test certificates, and statutory maintenance logs required for audits (ISO 9001/14001/45001, Factory Inspectorate).
• Track and manage shift-level inventory usage; raise material requisitions (MRNs) for spare parts drawn from the central engineering store.
• Deliver clear, structured shift-handover briefings covering running equipment status, isolated circuits, pending work permits, and critical alerts.

5. Safety, Statutory & Team Leadership

• Strictly enforce the plant's Permit-to-Work (PTW) system, ensuring proper mechanical line blinding, electrical Lockout-Tagout (LOTO), zero-energy verification, and gas testing prior to issuing clearance for work.
• Conduct toolbox talks (TBT) at the start of each shift covering job safety analysis (JSA), appropriate PPE usage, and specific shift hazards (working at heights, hot work, confined spaces).
• Supervise, guide, and allocate shift technical personnel (welders, fitters, electricians, instrumentation technicians) across planned preventive tasks and immediate breakdown calls.

Candidate Qualifications & Requirements

Educational Background:

• Diploma or B.E. / B.Tech in Mechanical, Electrical, or Instrumentation & Control Engineering from a recognized polytechnic or university.

Experience:

• 4 to 9 years of hands-on experience in continuous process plant maintenance (e.g., Distilleries/Ethanol, Chemical, Power Plants, Petrochemicals, Pharma, or Heavy Manufacturing).
• Minimum 2 to 3 years operating independently as a Shift Engineer, Shift In-charge, or Multi-Skilled Maintenance Supervisor.

Technical Competencies & Skills:

• Strong multi-disciplinary troubleshooting skills across mechanical rotary equipment, LT electrical switchboards, and field instrumentation.
• Ability to read and interpret engineering drawings: P&IDs, equipment general arrangement (GA) drawings, electrical schematics, loop diagrams, and cable termination schedules.
• Solid hands-on proficiency with basic diagnostic tools (mustimeters, clamp meters, megohmmeter/Megger, infrared thermometers, vibration pens).
• Working proficiency in computer applications: Microsoft Excel/Word, email reporting, and ERP/CMMS systems (such as SAP PM, ERP Next, Maximo, or similar maintenance software).

Key Performance Indicators (KPIs):

• Mean Time to Repair (MTTR) and plant maintenance-related downtime during shifts.
• On-time completion of scheduled preventive maintenance (PM) routines assigned to the shift.
• 100% compliance with PTW, LOTO, and shift safety protocols (zero safety incidents).
• Timeliness and accuracy of shift documentation, breakdown reports, and ERP spare consumption entries.