– MAINTENANCE MANAGER

Designation: Maintenance Manager

Department: Maintenance

Industry: Fasteners / Auto Components Manufacturing

Experience: Minimum 15 Years

Qualification: B.E./B.Tech – Mechanical / Electrical / Mechatronics

Reporting To: Plant Head / General Manager

1. Job Purpose

To lead and manage the complete maintenance function of the fasteners manufacturing plant, ensuring maximum machine availability, minimum breakdowns, effective preventive maintenance, cost control and secure operation of all production and utility equipment. The role will be responsible for maintenance activities covering Cold Forging, Thread Rolling, Heat Treatment (HT), Surface Treatment (ST), utilities and supporting equipment.

1. Key ResponsibilitiesA. Maintenance Management

- Lead the overall Mechanical, Electrical and Utility Maintenance functions.
- Develop and implement preventive, predictive and breakdown maintenance systems.
- Ensure maximum availability and reliability of production machinery.
- Monitor machine breakdowns, downtime, MTBF and MTTR.
- Conduct daily review of breakdowns and take corrective actions to prevent recurrence.
- Develop annual maintenance plans, shutdown plans and maintenance budgets.
- Establish maintenance standards, SOPs, checklists and machine history records.

B. Cold Forging Maintenance
- Manage maintenance of cold heading / cold forging machines, headers, formers and related equipment.
- Ensure proper maintenance of mechanical systems including gearboxes, bearings, clutches, brakes, shafts, cams, dies and lubrication systems.
- Troubleshoot recurring machine problems and improve machine reliability.
- Coordinate with Production and Tool Room teams for machine performance improvement.

C. Threading / Thread Rolling
- Ensure reliable operation of thread rolling machines and associated equipment.
- Monitor mechanical alignment, hydraulic/pneumatic systems, rollers, bearings, gearboxes and lubrication systems.
- Reduce breakdowns and improve machine availability through preventive maintenance.

D. Heat Treatment (HT)
- Lead maintenance activities for heat treatment furnaces, quenching systems, tempering furnaces, conveyors, burners,



cooling systems and associated utilities.
- Ensure preventive maintenance of furnace mechanical and electrical systems.
- Coordinate with Production and Quality teams to avoid process interruptions.
- Support energy-saving and furnace efficiency improvement initiatives.

E. Surface Treatment (ST)
- Manage maintenance of surface treatment / plating lines, chemical process equipment, pumps, tanks, conveyors, filters, blowers and associated systems.
- Ensure reliable operation of ETP and related utility equipment.
- Monitor corrosion-related maintenance requirements and ensure timely replacement/repair of critical components.
- Ensure maintenance activities are carried out without compromising safety and environmental requirements.

F. Utilities & Infrastructure
- Manage maintenance of air compressors, DG sets, cooling towers, pumps, HVAC, water systems, electrical systems and other plant utilities.
- Ensure uninterrupted availability of critical utilities.
- Develop utility preventive-maintenance schedules and monitor energy consumption.
- Coordinate with external service providers and OEMs for specialized maintenance.

1. Breakdown & Root Cause Analysis

- Ensure immediate response to critical machine breakdowns.
- Conduct Root Cause Analysis (RCA) for major and repeated breakdowns.
- Implement permanent corrective and preventive actions.
- Maintain breakdown history and analyze recurring failures.
- Develop critical-machine and critical-spare strategies.
- Reduce unplanned downtime and maintenance costs.

1. Preventive & Predictive Maintenance

- Develop monthly, quarterly and annual PM schedules.
- Ensure 100% completion of planned preventive maintenance.
- Implement condition monitoring wherever applicable.
- Monitor MTBF, MTTR, machine availability and maintenance cost.




- Introduce predictive maintenance techniques to reduce unexpected failures.

1. Spare Parts & Cost Control

- Identify and maintain inventory of critical spare parts.
- Control maintenance consumables and spare-parts costs.
- Coordinate with Purchase and Stores for timely procurement.
- Develop alternate sources for critical components.
- Evaluate repair versus replacement decisions.
- Prepare and control the annual maintenance budget.

1. Team Management

- Lead and develop the Maintenance team consisting of engineers, supervisors, technicians and operators.
- Allocate manpower according to shift and production requirements.
- Conduct skill-gap analysis and arrange technical training.
- Ensure proper shift handover and maintenance communication.
- Evaluate team performance and set individual KPIs.
- Develop multi-skilled maintenance technicians.

1. Projects & Continuous Improvement

- Support installation, commissioning and validation of new machines.
- Review technical specifications of new machinery and equipment.
- Coordinate with OEMs during machine installation and commissioning.
- Drive Kaizen, TPM, 5S and continuous improvement initiatives.
- Identify opportunities for automation, energy saving and machine efficiency improvement.
- Improve OEE through maintenance-related initiatives.

1. Safety & Compliance

- Ensure strict compliance with plant safety procedures during maintenance activities.
- Implement LOTO (Lockout/Tagout) procedures wherever required.
- Ensure safe maintenance of electrical, mechanical, hydraulic and pneumatic systems.
- Ensure statutory inspection and maintenance of applicable equipment.
- Participate in safety audits and close maintenance-related observations.

1. Documentation & Reporting

Maintain and review:
- Daily breakdown reports.
- Preventive maintenance reports.
- Machine history cards.
- MTBF / MTTR reports.
- Spare-parts consumption reports.
- Maintenance cost reports.
- Annual maintenance plans.
- Shutdown maintenance reports.
- Utility consumption and performance reports.
- RCA and corrective-action reports.

Pay: ₹60,000.00 - ₹75,000.00 per month

Work Location: In person

📌 Maintenance Manager (Anekal)
🏢 M.K.Fasteners
📍 Anekal