Senior Manager - Maintenance & Utility

Modern Insulators; Abu Road; On-site; INR 4,500,000 - 6,000,000; Full time

Job summary

Modern Insulators Ltd. in Abu Road, Rajasthan, seeks a Senior Manager Mechanical Maintenance & Utility to lead maintenance and utility strategies across pre-kiln, kiln, and post-kiln processes.

You will drive preventive, predictive and breakdown maintenance while ensuring high equipment availability and plant uptime. The role requires 15+ years in mechanical maintenance within continuous process industries, with at least 5 years in leadership.

Qualifications

• B.E./B.Tech in Mechanical Engineering (Mandatory)
• Minimum 15 years of experience in Mechanical Maintenance in a continuous process manufacturing industry
• Minimum 5 years of experience in leading a large maintenance team
• Hands-on experience in TPM, Reliability Engineering, Shutdown Planning and Utility Management

Responsibilities

• Manage Mechanical Maintenance & Utility function to ensure maximum equipment reliability and uninterrupted production.
• Oversee Pre-Kiln, Kiln and Post-Kiln operations for reliable performance.
• Lead safety, TPM, maintenance planning and cost optimization across all sections.
• Coordinate shutdown planning with Production, Electrical and Projects teams.
• Drive continuous improvement and MTBF/MTTR reduction across the plant.

Skills

TPM

Reliability Engineering

Shutdown Planning

Utility Management

Education

B.E./B.Tech in Mechanical Engineering

Tools

AutoCAD

SAP PM / CMMS

Job description

JOB DESCRIPTION

Position: Senior Manager Mechanical Maintenance & Utility

Department: Mechanical Maintenance & Utility

Location: Modern Insulators Ltd., Abu Road, Rajasthan

Qualification

• B.E./B.Tech in Mechanical Engineering (Mandatory)

Experience

• Minimum 15 years of experience in Mechanical Maintenance in a continuous process manufacturing industry, preferably Porcelain Insulators, Ceramics, Cement, Glass, Refractories, Chemical, Steel, Power or similar process industries.
• Minimum 5 years of experience in leading a large maintenance team.
• Hands-on experience in TPM, Reliability Engineering, Shutdown Planning and Utility Management.

Job Purpose

To manage Mechanical Maintenance & Utility function, ensuring maximum equipment reliability, uninterrupted production, optimum utility availability and continuous improvement across Pre-Kiln, Kiln and Post-Kiln manufacturing operations through effective preventive, predictive and breakdown maintenance practices.

Key Responsibilities

1. Mechanical Maintenance Pre-Kiln Operations

Responsible for the maintenance, reliability and performance improvement of equipment installed in:

• Slip House
• PED
• IED
• Shaping
• Dryer
• Glazing
• Material Handling Systems
• Conveyors
• Mixing & Preparation Equipment
• Pumps and Agitators
• Hydraulic & Pneumatic Systems

Ensure:

• Zero production loss due to mechanical failures.
• High machine availability.
• Timely preventive maintenance.
• Reduction in repetitive breakdowns.
• Improvement in equipment reliability.

2. Mechanical Maintenance Kiln Section

Responsible for complete maintenance of:

• Shuttle Kilns
• Kiln Cars
• Car Transfer Systems
• Kiln Drive Systems
• Burners & Combustion Equipment
• Refractory Maintenance
• Cooling Systems
• Fuel Distribution Systems
• Kiln Mechanical Structures
• Chain & Roller Mechanisms

Key Responsibilities:

• Ensure uninterrupted kiln operation.
• Plan annual kiln shutdowns.
• Improve kiln availability.
• Reduce emergency stoppages.
• Coordinate with Production for shutdown planning.

3. Mechanical Maintenance Post-Kiln Operations

Responsible for maintenance of all equipment related to:

• Cutting & Grinding Machines
• CNC/Conventional Grinding Equipment
• Assembly Lines
• Cementing Machines
• Galvanized Fitting Assembly Equipment
• Hydraulic Presses
• Testing Equipment
• Electrical & Mechanical Test Benches
• Inspection Equipment
• Material Handling Equipment
• Packing Line Equipment

Ensure:

• Continuous production support.
• Optimum machine utilization.
• Improved equipment accuracy.
• Reduction in rejection due to equipment failure.

4. Utility Management

Responsible for ensuring uninterrupted operation and maintenance of:

• Air Compressors
• Boiler
• Thermic Fluid Heater
• DG Sets
• Cooling Towers
• Industrial Water Supply
• Pumps
• Air Distribution Network
• Fuel Handling System
• Chilled Water Systems (where applicable)
• HVAC Systems
• Industrial Piping Network

Ensure:

• 100% utility availability.
• Energy-efficient operation.
• Preventive maintenance of utility equipment.
• Reduced utility downtime.

5. Preventive & Predictive Maintenance

• Develop Annual Maintenance Calendar.
• Ensure 100% PM schedule compliance.
• Implement Predictive Maintenance techniques.
• Introduce vibration analysis, thermography and condition monitoring.
• Improve MTBF and reduce MTTR.
• Develop maintenance SOPs and checklists.

6. TPM & Reliability Engineering

Lead TPM implementation across all maintenance functions.

Drive:

• Planned Maintenance Pillar
• Autonomous Maintenance Support
• Focused Improvement Projects
• Breakdown Analysis
• Kaizen Activities
• Equipment Reliability Improvement
• OEE Enhancement

7. Shutdown Planning

• Prepare annual shutdown plans.
• Execute preventive overhauls.
• Coordinate with Production, Electrical and Projects teams.
• Ensure shutdown completion within planned timelines and budgets.

8. Spare Parts & Inventory Management

• Identify critical mechanical spares.
• Optimize spare inventory.
• Develop minimum and maximum stock levels.
• Vendor development for critical equipment.
• Reduce inventory carrying cost.

9. Cost Optimization

• Prepare Annual Maintenance Budget.
• Monitor maintenance expenditure.
• Reduce maintenance cost per MT of production.
• Improve machine life through reliability initiatives.
• Optimize manpower and contractor utilization.

10. Team Leadership

Lead and develop:

• Maintenance Engineers
• Shift Engineers
• Supervisors
• Technicians
• Utility Team
• Contract Maintenance Workforce

Responsibilities include:

• Performance Management
• Skill Development
• Training Planning
• Competency Assessment
• Succession Planning

11. Safety, Quality & Compliance

Ensure compliance with:

• Factory Act
• Safety Standards
• Permit to Work (PTW)
• LOTO Procedures
• TPM Standards
• ISO Systems
• Environmental Regulations

Promote Zero Accident culture.

12. Cross Functional Coordination

Coordinate closely with:

• Production (Pre-Kiln)
• Kiln Operations
• Post-Kiln Production
• Quality Assurance
• Projects
• Purchase
• Stores
• EHS
• Finance

to achieve production and maintenance objectives.

Key Performance Indicators (KPIs)

• Overall Equipment Availability
• Plant Mechanical Downtime
• Machine Breakdown Hours
• MTBF
• MTTR
• Preventive Maintenance Compliance
• Utility Availability
• Kiln Availability
• OEE Improvement
• Breakdown Frequency Reduction
• Spare Inventory Turnover
• Maintenance Cost per MT Production
• Shutdown Adherence
• Energy Consumption
• Safety Performance
• TPM Planned Maintenance Score

Technical Competencies

• Mechanical Maintenance of Continuous Process Plants
• Utility Management
• Shuttle Kiln Maintenance
• Hydraulic & Pneumatic Systems
• Pumps, Gearboxes & Compressors
• Conveyors & Material Handling Systems
• Bearings & Lubrication Management
• Reliability Engineering
• TPM
• RCA / Why-Why Analysis / Fishbone
• FMEA
• SAP PM / CMMS
• AutoCAD (Preferred)
• MS Excel & Maintenance MIS

Behavioural Competencies

• Strong Leadership
• Strategic Planning
• Analytical Thinking
• Decision Making
• Problem Solving
• Team Building
• Communication & Coordination
• Result Orientation
• Continuous Improvement Mindset
• Cost Consciousness
• Change Management

Preferred Industry Background

• Porcelain Insulator Manufacturing
• Ceramic Industry
• Sanitaryware
• Refractories
• Cement
• Glass
• Steel
• Chemical
• Power
• Other Continuous Process Manufacturing Industries