Role & responsibilities

Particulars

Details

Designation / Position

Sr. Manager / DGM Maintenance

Department

Engineering & Maintenance

Job Location

Patancheru Hyderabad, Telangana

Industry

Chemical Manufacturing / Pharma

Experience

1520 Years

Qualification

B.E./B.Tech. in Mechanical or Electrical Engineering

Reporting To

Plant Head / Unit Head

Position Summary The Sr. Manager / DGM – Maintenance will be responsible for leading the Engineering & Maintenance function of the chemical/pharmaceutical manufacturing plant. The role involves ensuring high equipment reliability and plant availability through effective preventive, predictive and breakdown maintenance, while maintaining strict compliance with safety, quality, environmental and statutory requirements.

The position will lead the maintenance team, manage plant utilities and critical equipment, drive continuous improvement initiatives, support new projects, control maintenance costs and ensure uninterrupted production through efficient planning, execution and monitoring of maintenance activities.

Key Responsibilities

1. Plant Maintenance & Equipment Reliability

- Lead and oversee all maintenance activities for the manufacturing plant, utilities and associated infrastructure.
- Ensure maximum availability, reliability and efficiency of production equipment and utility systems.
- Plan, schedule and execute preventive, predictive and breakdown maintenance activities.
- Minimize equipment breakdowns, downtime and production losses through effective maintenance strategies.
- Monitor equipment performance and implement corrective and preventive actions.
- Maintain equipment history cards, maintenance records and relevant technical documentation.
- Develop and implement equipment reliability improvement programs.
- Ensure proper maintenance practices with minimum wastage, equipment damage and maintenance-related losses.

2. Mechanical Maintenance Hands-on knowledge and experience in maintenance of:

- Reactors and process equipment
- Centrifugal and positive displacement pumps
- Gearboxes and agitators
- Compressors and associated systems
- Pipelines, valves and fittings
- Heat exchangers
- Insulation systems
- Storage tanks and other process equipment
- Mechanical utility systems

3. Electrical & Instrumentation

- Oversee electrical maintenance activities across the plant.
- Ensure electrical systems, motors, MCCs, panels, transformers and associated equipment are maintained effectively.
- Drive electrical safety standards and improvement initiatives.
- Coordinate instrumentation maintenance and troubleshooting activities.
- Ensure calibration and maintenance of measuring and testing instruments.
- Support troubleshooting of electrical and instrumentation-related breakdowns.
- Ensure compliance with applicable electrical safety requirements.

4. Utilities Management Manage maintenance and operational reliability of major plant utility systems, including:

- Steam boilers and associated systems
- Chilling plants
- Air compressors
- Cooling towers
- DM/MB water treatment plants
- HVAC systems, where applicable
- Utility pipelines and distribution systems
- Other critical plant utility equipment

Ensure reliable and cost-effective operation of utilities to support uninterrupted production. 5. Preventive & Predictive Maintenance

- Develop and implement annual/monthly preventive maintenance plans.
- Establish equipment-wise maintenance schedules and checklists.
- Implement condition monitoring techniques for critical equipment.
- Analyze recurring breakdowns and identify root causes.
- Conduct Root Cause Analysis (RCA) for major equipment failures.
- Implement corrective and preventive actions and track their effectiveness.
- Drive predictive maintenance and reliability improvement initiatives.

6. Projects, Erection & Commissioning

- Provide engineering support for new projects and plant expansion activities.
- Participate in equipment selection,



specification and technical evaluation.
- Coordinate erection, installation, commissioning and qualification of current equipment.
- Ensure projects are completed safely, within budget and according to approved specifications.
- Support internal development and process improvement projects.
- Identify opportunities for plant modification, automation, energy conservation and equipment improvement.

7. Safety, Quality & Compliance

- Ensure strict adherence to plant safety, health and environmental requirements.
- Promote safe maintenance practices and permit-to-work systems.
- Drive electrical and mechanical safety improvement initiatives.
- Ensure maintenance activities comply with applicable statutory and regulatory requirements.
- Liaise with statutory authorities and regulatory agencies as required.
- Ensure timely renewal/maintenance of statutory approvals, licenses and certifications related to Engineering & Maintenance.
- Support integrated ISO systems covering Quality, Environment and Occupational Health & Safety.
- Ensure proper implementation of corrective and preventive actions arising from audits, inspections and incidents.

8. AMC, Contractors & Vendor Management

- Identify, evaluate and finalize competent agencies/vendors for AMC and specialized maintenance services.
- Manage annual maintenance contracts for critical equipment.
- Evaluate and approve mechanical, electrical, instrumentation and civil contractors.
- Monitor contractor performance, quality, safety and adherence to schedules.
- Ensure contractors comply with plant safety and work procedures.

9. Maintenance Planning, Budgeting & Cost Control

- Prepare annual maintenance budgets covering spares, manpower, services, equipment and projects.
- Control maintenance costs without compromising equipment reliability or safety.
- Plan and maintain adequate inventory of critical spares.
- Ensure timely procurement of required spare parts, equipment and consumables.
- Identify opportunities for cost reduction and energy savings.
- Monitor maintenance KPIs and departmental performance.

10. Team Leadership & People Development

- Lead, supervise and motivate the Engineering & Maintenance team.
- Plan manpower deployment and maintenance resources effectively.
- Establish clear roles, responsibilities and performance expectations.
- Conduct regular performance reviews and provide technical guidance.
- Identify training requirements and arrange technical, safety and behavioral training.
- Develop a competent and multi-skilled maintenance team.
- Promote teamwork, accountability, discipline and continuous improvement.

11. Continuous Improvement

- Drive continuous improvement initiatives in maintenance, reliability, safety and energy efficiency.
- Identify opportunities for reducing breakdowns, maintenance costs and energy consumption.
- Implement improvement projects using appropriate problem-solving methodologies.
- Encourage innovative ideas for equipment and process improvements.
- Establish best maintenance practices and standard operating procedures.

12. Documentation & Maintenance Systems

- Ensure proper maintenance documentation and records.
- Maintain equipment history, preventive maintenance records and breakdown reports.
- Ensure timely updating of maintenance databases/CMMS or other maintenance management systems.
- Monitor maintenance KPIs such as:

- Equipment availability

- Breakdown frequency

- MTBF

- MTTR

- Preventive maintenance compliance

- Maintenance cost

- Utility consumption

- Critical equipment reliability





Key Technical Competencies The ideal candidate should have strong practical knowledge of:

- Chemical/pharmaceutical plant maintenance
- Mechanical and electrical maintenance
- Process equipment and reactors
- Pumps, compressors and gearboxes
- Piping and utility systems
- Boilers and chilling plants
- Cooling towers
- DM/MB water treatment systems
- Preventive and predictive maintenance
- Condition monitoring
- Root Cause Analysis
- Electrical safety
- Instrumentation and calibration
- Erection and commissioning
- Project execution
- Maintenance planning and budgeting
- AMC and contractor management
- Statutory compliance
- ISO Quality, Environment & Safety systems
- Energy conservation and reliability improvement

Qualification & Experience

- B.E./B.Tech. in Mechanical or Electrical Engineering from a recognized institution.
- 15–20 years of overall experience in Engineering & Maintenance, preferably in a chemical/pharmaceutical manufacturing plant.
- Proven experience in leading the Engineering/Maintenance function of a manufacturing facility.
- Strong hands-on exposure to mechanical, electrical, instrumentation and utility maintenance.
- Experience in managing maintenance teams, contractors, vendors and maintenance budgets.
- Experience in project execution, equipment installation and commissioning will be preferred.

Behavioral & Leadership Competencies

- Strong leadership and team management skills.
- Excellent verbal and written communication.
- Strong analytical and problem-solving abilities.
- Good interpersonal and stakeholder management skills.
- Ability to work effectively under pressure and in a production-driven environment.
- Strong decision-making and troubleshooting capabilities.
- Ability to motivate and develop team members.
- Strong focus on safety, quality, reliability and cost optimization.
- Good computer skills, including MS Word, Excel and maintenance-related software/CMMS.
- Ability to work collaboratively with Production, Quality, EHS, Projects, Procurement and other functions.

Key Performance Indicators (KPIs) The position will be measured on:

- Reduction in equipment breakdowns and unplanned downtime.
- Improvement in plant and equipment availability.
- Preventive maintenance compliance.
- Improvement in MTBF and reduction in MTTR.
- Maintenance cost optimization.
- Critical spare availability and inventory control.
- Utility reliability and energy efficiency.
- Timely completion of maintenance projects.
- Compliance with statutory, safety, quality and environmental requirements.
- Successful implementation of continuous improvement initiatives.
- Team capability development and training effectiveness.

Safety & Compliance Accountability The incumbent will be accountable for ensuring that all Engineering & Maintenance activities are carried out in accordance with company policies, applicable statutory requirements and established Health, Safety & Environment (HSE) standards. Particular emphasis will be placed on electrical safety, mechanical safety, permit-to-work systems, contractor safety, secure isolation/LOTO practices, statutory compliance and safe maintenance procedures.

Overall Accountability The Sr. Manager / DGM – Maintenance will be accountable for the overall reliability, availability, safety and cost-effective maintenance of the plant's production equipment, utilities and engineering infrastructure. The incumbent will work closely with Production and other cross-functional teams to ensure uninterrupted manufacturing operations while continuously improving plant reliability, safety, quality and operational efficiency.

Note The above responsibilities represent the minimum requirements of the position. Additional duties and responsibilities may be assigned by the Department Head or Management based on operational requirements. This document serves as a guideline and is subject to revision and modification as required by the organization

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