MANAGER - MAINTENANCE

Sansera Engineering Limited; Bengaluru; On-site; INR 3,500,000 - 5,500,000; Full time

Job summary

Sansera Engineering Limited seeks a senior leader to head machine shop maintenance, utilities, and special process equipment ensuring high availability and safe operation. You will implement preventive, predictive, and breakdown maintenance, driving productivity, cost optimization, and continuous improvement across the plant.

You will develop annual maintenance plans, manage budgets and spares, monitor OEE, MTBF, MTTR, and lead root-cause analysis for critical equipment failures.

Qualifications

• 15–20 years of experience in Maintenance / Engineering functions.
• Experience in Automotive, Aerospace, Precision Machining, or Engineering Manufacturing preferred.
• Proven experience in managing a large maintenance team and multiple manufacturing assets.
• Strong knowledge of CNC machines, machining centers, and manufacturing equipment.
• Knowledge of SAP / CMMS / ERP-based maintenance systems.
• Familiarity with statutory compliance and industrial safety requirements.

Responsibilities

• Lead and manage maintenance activities for machines, equipment, utilities, and plant infrastructure.
• Develop and implement preventive, predictive, and breakdown maintenance strategies.
• Ensure maximum machine availability and minimum unplanned downtime.
• Monitor equipment performance metrics like OEE, MTBF, and MTTR.
• Plan annual maintenance budgets, manpower, and resources.
• Coordinate with Production, Engineering, Quality, and external vendors for maintenance needs.
• Drive TPM, 5S, Kaizen, and energy-conservation initiatives.
• Oversee commissioning and maintenance of new equipment and expansion projects.

Skills

Leadership

Team management

Project management

Vendor management

Root cause analysis

TPM / maintenance excellence

OEE, MTBF, MTTR

Energy management

Cost optimization

Problem solving

Cross-functional coordination

Education

BE / B.Tech in Mechanical / Electrical / Electronics / Mechatronics

Tools

SAP

CMMS

ERP-based maintenance systems

Job description

To lead the overall machine shop maintenance, utility services along with special process equipment ensure high availability, reliability, and safe operation of machines, utilities, infrastructure, and equipment by implementing maintenance strategy preventive, predictive, and breakdown maintenance systems while driving productivity, cost optimization, and continuous improvement.

JOB DESCRIPTION / RESPONSIBILITIES

• Lead and manage overall maintenance activities for machines, equipment, utilities, and plant infrastructure.
• Develop and implement preventive, predictive, and breakdown maintenance strategies.
• Ensure maximum machine availability and minimum unplanned downtime.
• Monitor and improve equipment OEE, MTBF, and MTTR.
• Develop annual maintenance plans, budgets, manpower plans, and resource requirements.
• Ensure preventive maintenance schedules are planned and completed within defined timelines.
• Analyse machine breakdowns and recurring failures and implement permanent corrective actions.
• Lead root cause analysis for critical equipment failures using appropriate problem-solving methodologies.
• Ensure timely availability of critical spare parts, tools, and maintenance consumables.
• Establish and maintain critical spare inventory and equipment history records.
• Coordinate with Production, Engineering, Quality, PPC, Stores, and external vendors for maintenance requirements.
• Manage installation, commissioning, qualification, and maintenance of new machines and equipment.
• Support capacity expansion, machine relocation, plant modifications, and infrastructure development projects.
• Ensure proper maintenance of CNC machines, machining centers, compressors, HVAC, electrical systems, DG sets, chillers, ETP/STP, and other utilities, as applicable.
• Monitor energy consumption and implement initiatives for energy conservation and cost reduction.
• Ensure compliance with statutory requirements related to electrical systems, pressure vessels, lifting equipment, fire safety, and other applicable requirements.
• Establish standard maintenance procedures, checklists, work instructions, and equipment records.
• Implement TPM, 5S, Kaizen, predictive maintenance, and reliability improvement initiatives.
• Evaluate new maintenance technologies and condition-monitoring techniques.
• Manage maintenance contractors and service providers and monitor their performance.
• Develop technical capability of maintenance engineers, technicians, and operators.
• Ensure adherence to safety procedures, PPE requirements, LOTO practices, and environmental standards.
• Prepare and review maintenance MIS, KPI dashboards, breakdown analysis, and management reports
• Drive maintenance cost optimization without compromising equipment reliability and safety.

AUTHORITY

• Prioritize maintenance activities based on equipment criticality and production requirements.
• Stop equipment operation where unsafe conditions or major equipment risks are identified.
• Approve routine maintenance activities, schedules, and resource allocation within defined authority.
• Recommend procurement of critical spares, tools, equipment, and maintenance services.
• Approve maintenance contractors and service activities within the approved scope.
• Escalate critical breakdowns, safety risks, and operational risks to senior management.
• Recommend machine replacement, modification, or technology upgrades based on reliability and lifecycle analysis.
• Allocate maintenance manpower and resources based on business priorities.

JOB SPECIFICATION / COMPETENCY

Educational Qualification

• BE / B.Tech in Mechanical / Electrical / Electronics / Mechatronics Engineering.
• Additional qualification in Maintenance Management, Reliability Engineering, or Operations Management is preferred.

Experience

• 15–20 years of experience in Maintenance / Engineering functions.
• Experience in Automotive, Aerospace, Precision Machining, or Engineering Manufacturing industries preferred.
• Proven experience in managing a large maintenance team and multiple manufacturing assets.
• Strong knowledge of CNC machines, machining centers, and manufacturing equipment.
• Good understanding of mechanical, electrical, hydraulic, pneumatic, PLC, servo, and automation systems.
• Strong knowledge of preventive, predictive, and breakdown maintenance.
• Expertise in TPM, OEE, MTBF, MTTR, RCA, and equipment reliability improvement.
• Knowledge of utility systems and plant infrastructure.
• Experience in maintenance planning, budgeting, spare-parts management, and cost control.
• Knowledge of SAP / CMMS / ERP-based maintenance systems.
• Familiarity with statutory compliance and industrial safety requirements.
• Knowledge of energy management and utility optimization.
• Strong project management and vendor management skills.
• Strong leadership and team management skills.
• Strategic thinking and decision-making ability.
• Excellent analytical and problem-solving skills.
• Strong communication and cross-functional coordination.
• High ownership and accountability.
• Ability to manage critical situations and work under pressure.
• Cost-conscious and improvement-oriented mindset.

PERFORMANCE MEASURES

• Machine availability and equipment reliability.
• Improvement in OEE and reduction in unplanned downtime.
• Reduction in machine breakdown frequency and duration.
• Improvement in MTBF and reduction in MTTR.
• Preventive and predictive maintenance schedule adherence.
• Reduction in repeat and chronic equipment failures.
• Maintenance cost optimization and budget adherence.
• Critical spare availability and inventory optimization.
• Utility availability and energy-cost reduction.
• Timely commissioning and stabilization of new machines/equipment.
• Compliance with statutory, safety, and environmental requirements.
• TPM, Kaizen, and continuous improvement achievements.
• Maintenance team productivity, skill development, and competency improvement.
• Vendor/service-provider performance and cost effectiveness.