Senior Maintenance Engineer

Horizon Industrial Products; Neemrana, Gurugram District; On-site; INR 900,000 - 1,400,000; Full time

Job summary

Horizon Industrial Products in Neemrana is seeking a Senior Maintenance Engineer to lead maintenance planning and execution for a sheet metal manufacturing plant. You will drive preventive and predictive maintenance, monitor MTTR and machine availability, and implement improvements across mechanical, electrical and automation domains.

The role encompasses dies, fixtures, tooling, spare parts, energy management and safety compliance, while heading a team of technicians and coordinating with

Responsibilities

• Develop and implement annual, monthly and daily maintenance plans.
• Ensure preventive and predictive maintenance is carried out as per schedule.
• Minimize machine breakdowns and production downtime.
• Monitor MTTR, machine availability and maintenance efficiency.
• Establish effective breakdown-response systems.
• Analyze recurring breakdowns and implement permanent corrective actions.
• Maintain equipment history and maintenance records.
• Maintain mechanical, electrical, hydraulic and automation equipment.
• Coordinate with production and quality teams for uptime optimization.
• Lead maintenance team during major breakdowns and ensure fast restoration of production.
• Manage spare parts inventory and uptime-related procurement.

Skills

Maintenance planning

Leadership

Team management

Job description

JOB DESCRIPTION SR. MAINTENANCE ENGINEER

Department: Maintenance / Engineering

Position: Maintenance Engineer

Reports To: HOD

Location: Sheet Metal Manufacturing Plant

Industry: Automotive / Engineering / Sheet Metal Components

Key Responsibilities

A. Maintenance Planning & Execution

• Develop and implement annual, monthly and daily maintenance plans.
• Ensure preventive and predictive maintenance is carried out as per schedule.
• Minimize machine breakdowns and production downtime.
• Monitor MTTR, machine availability and maintenance efficiency.
• Establish effective breakdown-response systems.
• Analyze recurring breakdowns and implement permanent corrective actions.
• Maintain equipment history and maintenance records.

B. Sheet Metal Machinery Maintenance

• Responsible for maintenance of:
• Mechanical / hydraulic / pneumatic power presses.
• Press brakes and shearing machines.
• Spot welding, MIG and other welding equipment.
• Robotic welding systems, where applicable.
• Compressors, air dryers and pneumatic systems.
• Pumps, motors, gearboxes and conveyors.
• EOT cranes, hoists and material-handling equipment.
• DG sets, electrical panels and distribution systems.
• HVAC, cooling systems and other utilities.
• Plant electrical, mechanical and utility infrastructure.

C. Electrical & Automation

• Ensure preventive maintenance of HT/LT electrical systems.
• Monitor electrical panels, MCCs, PCCs, transformers, motors and drives.
• Ensure PLC, HMI, sensors, VFD and automation-system reliability.
• Coordinate troubleshooting of electrical and automation failures.
• Maintain proper electrical safety and statutory compliance.
• Monitor power consumption and identify energy-saving opportunities.

D. Preventive & Predictive Maintenance

• Prepare equipment-wise preventive-maintenance checklists.
• Establish maintenance frequencies based on OEM recommendations and machine history.
• Implement condition monitoring such as vibration, temperature, oil condition and electrical health checks where applicable.
• Ensure timely replacement of wear parts, bearings, seals, belts, chains and other critical components.
• Develop critical-spares and preventive-replacement plans.

E. Breakdown Management

• Lead the maintenance team during major breakdowns.
• Ensure quick response and restoration of production.
• Conduct Root Cause Analysis (RCA) for major and repetitive failures.
• Implement CAPA to prevent recurrence.
• Track breakdown hours and identify top loss-making machines.

F. Dies, Fixtures & Tooling Support

• Coordinate maintenance and repair of production dies, fixtures and tooling.
• Ensure timely availability of dies and fixtures for production.
• Improve die/fixture life through preventive maintenance.
• Coordinate with Tool Room, Production and Quality teams for recurring tooling issues.

G. Spare Parts & Inventory Management

• Identify critical machine spares and maintain minimum stock levels.
• Control maintenance inventory and avoid unnecessary purchases.
• Develop alternate/local sources for critical components.
• Review spare consumption and obsolete inventory.
• Coordinate with Purchase and Stores for timely procurement.

H. Team Management

• Lead, train and develop maintenance engineers, supervisors, electricians, fitters and technicians.
• Allocate manpower according to shift and equipment requirements.
• Establish clear responsibilities and escalation procedures.
• Conduct skill-gap analysis and technical training.
• Ensure discipline and adherence to maintenance procedures.

I. Safety & Compliance

• Ensure compliance with plant safety procedures.
• Implement LOTO (Lockout/Tagout) practices during maintenance.
• Ensure safe working practices for electrical, mechanical, welding and height-related maintenance activities.
• Conduct periodic safety inspections.
• Ensure statutory inspections and certifications of applicable equipment such as cranes, pressure systems and electrical installations.
• Investigate maintenance-related accidents and implement corrective actions.

J. Cost Control & Energy Management

• Prepare and control the maintenance budget.
• Reduce breakdown, spare-parts and repair costs.
• Monitor maintenance cost per machine / production unit.
• Identify energy-saving opportunities.
• Reduce compressed-air leakage, power losses and utility wastage.
• Evaluate repair-vs-replacement decisions for major equipment.

K. Continuous Improvement

• Implement TPM, 5S, Kaizen and Lean Maintenance practices.
• Improve OEE through better machine reliability.
• Identify chronic losses and develop improvement projects.
• Standardize maintenance procedures and checklists.
• Drive automation and condition-monitoring initiatives where economically justified.

L. Documentation & Reporting

• Preventive-maintenance schedules.
• Breakdown reports.
• Machine history cards.
• MTBF / MTTR reports.
• Machine availability reports.
• Spare-parts records.
• Maintenance cost reports.
• RCA and CAPA reports.
• Annual maintenance plans and budgets.
• Utility consumption reports.
• Statutory inspection records.