Job Description

Position: Maintenance Manager

Department: Maintenance

Industry: Automotive Assembly Plant

Reports To: Plant Head / Operations Head

Qualification: Diploma/B.Tech/B.E. in Mechanical, Electrical, Electronics, or Mechatronics Engineering.

Experienc : 8 to 18 Year

Job Purpose

To ensure maximum machine availability, reliability, and efficiency by effectively managing preventive, predictive, and breakdown maintenance activities while supporting production, new projects, utilities, quality systems, and continuous improvement initiatives.

Key Responsibilities

1. Maintenance Planning & Execution

- Plan and monitor daily maintenance activities.
- Prepare and control daily job planning.
- Ensure timely completion of all pending maintenance work.
- Maintain machine history and maintenance records.

2. Preventive & Predictive Maintenance

- Develop and implement Preventive Maintenance (PM) schedules.
- Execute Predictive Maintenance (PdM) activities.
- Improve machine reliability through root cause analysis and corrective actions.
- Ensure zero overdue PM activities.

3. Breakdown Maintenance

- Attend all critical and major machine breakdowns immediately.
- Lead troubleshooting of electrical, mechanical, pneumatic, hydraulic, and PLC-related issues.
- Minimize machine downtime and improve MTTR.
- Conduct Root Cause Analysis (RCA) and implement permanent countermeasures.

4. PLC & Automation

- Troubleshoot PLC-related machine breakdowns.
- Modify and maintain PLC programs as required.
- Support automation improvements and machine optimization.

5. Spare Parts Management

- Maintain critical spare parts inventory.




- Ensure availability of all essential spare parts.
- Prepare material indents for maintenance requirements.
- Monitor spare consumption and optimize inventory costs.

6. New Projects & Line Setup

- Prepare BOM for new assembly lines.
- Raise new line material indents.
- Support machine manufacturing and assembly.
- Coordinate installation, commissioning, and validation of new equipment.
- Conduct new machine trials.
- Manage machine shifting and reinstallation.
- Prepare and modify production line layouts.

7. Utility Maintenance

- Ensure uninterrupted operation of utilities such as compressors, power supply, lighting, cooling systems, and other plant services.
- Attend utility breakdowns on priority.
- Maintain all utility equipment in healthy operating condition.

8. Equipment Repair

- Supervise repair and maintenance of:
- Motors
- Fans
- Coolers
- Emergency Lights
- Load Cells
- Display Units
- Control Panels
- Electrical & Mechanical Equipment
- Other plant machinery and accessories

9. Quality & Process Improvement

- Ensure effective implementation of Poka-Yoke systems.
- Conduct weekly drop tests as per customer requirements.
- Support continuous improvement and Kaizen activities.
- Improve OEE through maintenance initiatives.

10.



Documentation & Audit

- Maintain all maintenance documentation and records.
- Prepare audit documents for customer, internal, and external audits.
- Update Daily DWM Board and maintenance KPIs.
- Ensure compliance with ISO, IATF 16949, 5S, TPM, and safety standards.

11. Team Management

- Lead and develop the maintenance team.
- Allocate manpower effectively.
- Train technicians in maintenance best practices.
- Monitor team performance and skill development.

12. Safety & Compliance

- Ensure secure maintenance practices.
- Conduct risk assessments before maintenance activities.
- Ensure compliance with statutory and company safety requirements.
- Promote Zero Accident and Zero Breakdown culture.

Key Performance Indicators (KPIs)

- Machine Availability
- Overall Equipment Effectiveness (OEE)
- Preventive Maintenance Compliance
- Breakdown Frequency
- Mean Time to Repair (MTTR)
- Mean Time Between Failures (MTBF)
- Utility Uptime
- Spare Inventory Accuracy
- Maintenance Cost Control
- Audit Compliance
- Poka-Yoke Effectiveness
- On-time Completion of Pending Work
- New Project Completion as per Timeline
- Team Productivity and Safety Performance

Reporting

Reports To: Plant Head / Operations Head

Qualification

- Diploma/B.Tech/B.E. in Mechanical, Electrical, Electronics, or Mechatronics Engineering.

Experience

- 8 to 18 years of maintenance experience in an Automotive Assembly Plant.
- Strong knowledge of PLCs, automation, TPM, preventive and predictive maintenance, utilities, and assembly line equipment.

📌 Maintenance Manager (Uttar Pradesh)
🏢 Dawnsun
📍 Uttar Pradesh