Senior Engineer - Mechanical Maintenance

AP Management Consultants; Puducherry; On-site; INR 500,000 - 700,000; Full time

Job summary

AP Management Consultants is seeking an experienced Maintenance Manager in Puducherry to plan and execute preventive, predictive, and breakdown maintenance for manufacturing equipment. You will drive TPM initiatives, lead a team of engineers and technicians, and ensure high uptime with effective spare parts management.

The role focuses on safety, compliance, and continuous improvement, including data-driven reporting of MTBF, MTTR, and OEE metrics.

Qualifications

• Experience in planning and executing preventive, predictive, and breakdown maintenance for manufacturing equipment.
• Ability to drive TPM and continuous improvement initiatives in production areas.
• Ability to conduct root cause analysis using 5 Why, Fishbone Diagram and Pareto Analysis.

Responsibilities

• Plan and execute preventive, predictive, and breakdown maintenance activities for manufacturing equipment.
• Ensure maximum machine uptime and minimize production losses.
• Analyze equipment failures and implement CAPA.
• Monitor machine performance and reliability indicators.
• Drive TPM activities across production areas and lead Kaizen initiatives.
• Develop annual, monthly, and weekly maintenance plans and coordinate with production teams.
• Monitor spare inventory levels and coordinate procurement of maintenance spares.
• Ensure compliance with EHS policies and conduct safety inspections.

Skills

Maintenance planning

Preventive maintenance

Root cause analysis

Team leadership

Documentation & reporting

Tools

CMMS/ERP systems

Job description

Role & responsibilities

1. Maintenance Management

• Plan and execute preventive, predictive, and breakdown maintenance activities for manufacturing equipment.
• Ensure maximum machine uptime and minimize production losses.
• Analyze equipment failures and implement corrective and preventive actions (CAPA).
• Monitor machine performance and reliability indicators.

2. Equipment Maintenance

Maintain and improve the performance of:

• Stator winding machines
• Coil insertion machines
• Commutator assembly machines
• Rotor balancing machines
• Press machines
• Hydraulic and pneumatic systems
• Conveyor systems
• Assembly line equipment
• Gear box, Index table, LM guides, Ball screws, clutches
• Utility systems (air compressors, chillers, cooling towers, pumps, etc.)
• Material handling equipment

3. TPM & Continuous Improvement

• Drive TPM (Total Productive Maintenance) activities across production areas.
• Implement Autonomous Maintenance (JH & PM Pillar) initiatives.
• Conduct root cause analysis using 5 Why, Fishbone Diagram, and Pareto Analysis.
• Lead Kaizen and cost-reduction projects.
• Support OEE improvement initiatives.

4. Planning & Scheduling

• Develop annual, monthly, and weekly maintenance plans.
• Coordinate maintenance schedules with production teams.
• Ensure timely completion of shutdown maintenance activities.

5. Spare Parts & Inventory Control

• Monitor critical spare inventory levels.
• Coordinate procurement of maintenance spares.
• Optimize spare consumption and maintenance costs.
• Maintain proper records of equipment history and spare utilization.

6. Safety & Compliance

• Ensure compliance with EHS policies and statutory requirements.
• Conduct safety inspections and risk assessments.
• Implement Lockout/Tagout (LOTO) procedures during maintenance activities.
• Ensure safe work practices among maintenance personnel and contractors.

7. Team Management

• Lead, guide, and develop maintenance engineers, technicians, and trainees.
• Conduct skill development and technical training programs.
• Evaluate team performance and support succession planning.

8. Documentation & Reporting

• Maintain maintenance records through CMMS/ERP systems.
• Prepare daily, weekly, and monthly maintenance reports.
• Track maintenance KPIs such as:

• MTBF (Mean Time Between Failures)
• MTTR (Mean Time To Repair)
• OEE (Overall Equipment Effectiveness)
• Maintenance Cost per Unit
• Preventive Maintenance Compliance

Preferred candidate profile

Location: Puducherry; Candidates who are native of Puducherry are also welcome