Position: Senior Manager Mechanical Maintenance & Utility

Department: Mechanical Maintenance & Utility

Location: Up-to-date 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

📌 Senior Manager - Maintenance & Utility (Abu Road)
🏢 Modern Insulators
📍 Abu Road