– Maintenance Head (Biscuit Manufacturing Industry)

Department - Engineering & Maintenance

Reporting To – Managing Director

Location – Hyderabad (Kattedan IDA) Biscuit Manufacturing Facility

Experience Required - 15+ Years of Progressive Experience in maintenance and engineering functions within the biscuit manufacturing industry, including at least 5 years in a senior leadership role managing plant-wide maintenance operations.

Position Summary The Maintenance Head is responsible for the overall reliability, availability, efficiency, and safety of all manufacturing assets within the biscuit production facility. The role ensures uninterrupted operation of biscuit production lines, ovens, mixing systems, packaging machines, utilities, and support infrastructure through effective preventive, predictive, and corrective maintenance programs.

The incumbent will lead multidisciplinary maintenance teams, oversee engineering projects,

ensure compliance with OSHAS/OHS regulations, food safety requirements, statutory standards, and drive continuous improvement initiatives to maximize equipment uptime,

reduce maintenance costs, and support production targets.

Key Responsibilities

- Plant Maintenance Management

 Develop and implement comprehensive maintenance strategies for all biscuit manufacturing equipment and utilities.

 Ensure maximum availability and reliability of production lines through preventive,

predictive, and breakdown maintenance.

 Establish maintenance schedules to minimize production interruptions.

 Monitor and improve Overall Equipment Effectiveness (OEE).

 Analyze equipment failures and implement corrective and preventive actions.

 Maintain maintenance records, logs, equipment histories, and performance reports.

 Ensure proper calibration and functionality of all critical process equipment.

- Biscuit Manufacturing Equipment Maintenance

Ensure efficient operation and maintenance of:

Dough Preparation Section

 Flour handling systems

 Sifters and conveyors

 Dough mixers

 Ingredient dosing systems

 Dough feeding systems

Biscuit Forming Section

 Rotary moulders

 Rotary cutters

 Sheeting and gauging systems

 Laminators

Baking Section

 Tunnel ovens

 Direct and indirect fired ovens

 Gas burners

 Temperature control systems

 Heat recovery systems

Cooling Section

 Cooling conveyors

 Air circulation systems

 Cooling tunnels

Packaging Section

 Automatic packing machines

 Flow wrap machines

 Cartoning machines

 Coding and printing systems

 Metal detectors

 Check weighers

 Case packing systems

Material Handling Systems

 Belt conveyors

 Pneumatic conveying systems

 Bucket elevators





 Pallet handling equipment

- Utilities Management

Manage operation and maintenance of:

 Electrical distribution systems

 DG sets and backup power systems

 Air compressors

 Boilers (where applicable)

 HVAC systems

 Water supply systems

 RO plants

 Softening plants

 Chillers

 Cooling towers

 Firefighting systems

 Effluent treatment systems

 Sewage treatment plants

 Industrial refrigeration systems

- Electrical & Electronics Maintenance

 Ensure reliable operation of HT/LT electrical systems.

 Manage transformers, switchgear, MCCs, PCC panels, and distribution networks.

 Supervise preventive maintenance of motors, drives, and electrical equipment.

 Troubleshoot electrical breakdowns affecting production.

 Ensure proper maintenance of PLC, SCADA, HMI, VFD, servo systems, sensors, and automation controls.

 Maintain power quality and energy efficiency standards.

 Ensure compliance with electrical safety regulations and statutory inspections.

- Instrumentation & Automation

 Maintain process automation systems throughout the biscuit manufacturing process.

 Monitor and troubleshoot PLC-controlled production lines.

 Ensure calibration and reliability of process instruments.

 Maintain temperature, pressure, flow, and weighing control systems.

 Support digitalization and Industry 4.0 initiatives where applicable.

- Mechanical Maintenance

 Manage maintenance of rotating and static equipment.

 Ensure reliability of gearboxes, motors, pumps, compressors, bearings, chains,

conveyors, and pneumatic systems.

 Monitor lubrication programs and condition monitoring activities.

 Implement predictive maintenance techniques including:

o Vibration analysis o Thermography o Oil analysis o Condition-based monitoring

- Plumbing & Facility Maintenance

 Oversee maintenance of plant water distribution systems.

 Ensure functionality of drainage systems and sanitary infrastructure.

 Manage compressed air piping networks.

 Maintain facility infrastructure, civil structures, roofing, flooring, and utility services.

 Ensure uninterrupted supply of process water and utilities.

- Safety, OSHAS & Regulatory Compliance

 Ensure compliance with OSHAS/OHS standards and company safety policies.





 Lead implementation of safe work practices across engineering activities.

 Conduct risk assessments and hazard identification programs.

 Implement Permit-to-Work (PTW) systems.

 Ensure adherence to Lockout/Tagout (LOTO) procedures.

 Conduct safety audits and inspections.

 Lead accident investigations and root cause analysis.

 Ensure compliance with fire safety regulations and emergency preparedness programs.

 Maintain statutory compliance for boilers, electrical installations, pressure vessels,

and utilities.

- Food Safety & Quality Compliance

 Support compliance with food safety standards including:

o HACCP o GMP o GHP o FSSC 22000

o ISO 22000

o BRCGS (where applicable)

 Ensure maintenance activities do not compromise product quality.

 Implement food-grade maintenance practices.

 Control contamination risks arising from engineering activities.

 Participate in internal and external audits.

- Team Leadership & Development

 Lead and manage maintenance engineers, supervisors, technicians, electricians,

fitters, and utility operators.

 Conduct technical and safety training programs.

 Foster a culture of accountability, teamwork, and continuous improvement.

 Coordinate with Production, Quality, Supply Chain, and EHS departments.

- Project Management & Continuous Improvement

 Lead installation, commissioning, and validation of current equipment.

 Execute plant expansion and modernization projects.

 Drive automation and energy-saving initiatives.

 Identify opportunities for productivity enhancement and cost reduction.

 Manage capital expenditure (CAPEX) and maintenance budgets.

- Vendor & Contractor Management

 Manage relationships with equipment manufacturers and service providers.

 Evaluate contractor performance and compliance.

 Negotiate annual maintenance contracts.

 Ensure quality execution of outsourced maintenance activities.

 Maintain critical spare parts inventory and vendor development programs.

Key Performance Indicators (KPIs)

 Equipment uptime %

 Plant availability %

 OEE improvement

 Breakdown frequency reduction

 Mean Time Between Failure (MTBF)

 Mean Time To Repair (MTTR)

 Maintenance cost per ton of production

 Energy consumption reduction

 Safety incident rate

 Preventive maintenance compliance %

 Spare parts inventory optimization

 Audit compliance score

 Production loss due to maintenance downtime

Required Qualifications

Education

 Bachelors Degree in Mechanical Engineering, Electrical Engineering, Electronics

Engineering, Industrial Engineering, or related discipline.

 Masters Degree preferred.

📌 Head Maintenance - Biscuit Chocolate Industry Only (Hyderabad)
🏢 Connecting Chains
📍 Hyderabad