Job Purpose To plan, schedule, monitor, and optimize all preventive, predictive, breakdown, shutdown, and capital maintenance activities to ensure maximum equipment availability, reliability, and protected operation while minimizing maintenance costs.

Key Responsibilities

1. Maintenance Planning & Scheduling · Prepare annual, monthly, weekly, and daily maintenance plans.

· Develop preventive maintenance (PM) schedules for all plant equipment.

· Coordinate predictive maintenance activities based on equipment condition monitoring.

· Plan major shutdowns and annual overhauls.

· Prepare detailed maintenance job plans including manpower, tools, spare parts, and estimated duration.

· Ensure timely execution of maintenance schedules with minimum disruption to production.

1. Equipment Reliability · Analyse equipment failures and recommend corrective and preventive actions.

· Improve equipment reliability through Root Cause Analysis (RCA).

· Monitor Mean Time Between Failures (MTBF) and Mean Time to Repair (MTTR).

· Implement reliability improvement initiatives and continuous improvement projects.

1. Shutdown Management · Prepare detailed shutdown schedules.

· Coordinate with Production, Electrical, Instrumentation, Stores, and contractors.

· Monitor shutdown progress and ensure completion within planned timelines.

· Prepare shutdown completion reports with observations and recommendations.

1. Spare Parts Planning · Identify critical spare parts for all mechanical equipment.

· Monitor inventory levels and initiate purchase requisitions.

· Coordinate with the Stores and Purchase departments to ensure spare availability.

· Optimize spare inventory without affecting equipment reliability.

1. Work Order Management · Generate and monitor maintenance work orders through SAP/CMMS.

· Prioritize work orders based on equipment criticality.





· Ensure proper closure of work orders with complete maintenance history.

· Maintain equipment records and maintenance documentation.

1. Budget & Cost Control · Prepare annual maintenance budgets.

· Monitor maintenance expenditure.

· Identify opportunities for cost reduction without compromising reliability.

· Control contractor and maintenance service costs.

1. Safety & Compliance · Ensure maintenance activities comply with statutory and company safety requirements.

· Enforce Permit-to-Work (PTW), Lock-Out/Tag-Out (LOTO), and confined space procedures.

· Conduct safety audits before and during maintenance activities.

· Ensure compliance with ISO, environmental, and statutory maintenance standards.

1. Team Coordination · Coordinate with Mechanical, Electrical, Instrumentation, Production, and Utility departments.

· Supervise planning engineers and maintenance coordinators.

· Coordinate external contractors during shutdowns and major repairs.

· Conduct daily maintenance planning and review meetings.

1. Continuous Improvement · Develop maintenance SOPs and standard job procedures.

· Implement TPM, RCM, Lean Maintenance, and 5S initiatives.

· Monitor maintenance KPIs and recommend improvement actions.

· Drive digitization and automation in maintenance planning.

Key Equipment

· Ferrous Shredder Plant

· Hydraulic Systems

· Conveyors

· Gearboxes

· Crushers

· Material Handling Equipment

· Scrap Feed Systems

· Dust Collection Systems

· Cooling Water Systems

· Pumps

· Compressors





· Industrial Fans & Blowers

· Structural Equipment

· Cranes and Hoists

Key Performance Indicators (KPIs)

· Equipment Availability (%)

· Preventive Maintenance Compliance (%)

· Breakdown Frequency

· MTBF

· MTTR

· Maintenance Cost per Ton

· Shutdown Completion as per Schedule

· Spare Parts Availability

· Work Order Closure Rate

· Safety Compliance

· Zero Major Maintenance Incidents

Educational Qualification

· B.E./B.Tech in Mechanical Engineering.

· Additional certification in Maintenance Planning, Reliability Engineering, or SAP PM will be an added advantage.

Experience

· 10–15 years of experience in mechanical maintenance, with at least 5 years in maintenance planning.

· Experience in steel plants, metal recycling plants, shredders, rolling mills, heavy engineering, cement, mining, or similar continuous-process industries.

· Hands-on experience with SAP PM or other Computerized Maintenance Management Systems (CMMS).

Required Skills

· Maintenance Planning & Scheduling

· Preventive & Predictive Maintenance

· Shutdown Planning

· SAP PM / CMMS

· Reliability Engineering

· Root Cause Analysis (RCA)

· Budget Management

· Spare Parts Management

· Team Leadership

· Project Coordination

· Technical Documentation

· Strong analytical and problem-solving skills

· Effective communication and cross-functional coordination

Behavioural Competencies

· Leadership

· Planning & Organizing

· Decision Making

· Accountability

· Teamwork

· Continuous Learning

· Time Management

· Result Orientation

· Safety Mindset

· Integrity

Working Conditions

· Plant-based role with frequent shop-floor visits.

· Availability during emergency breakdowns and planned shutdowns.

- · Coordination with multiple departments and contractors.

📌 Manager/ Sr Manager Mechanical Maintenance Planning (Rohtak)
🏢 Aarti Green Tech
📍 Rohtak