Manager – Mechanical Maintenance

Department: Maintenance

Function: Mechanical Maintenance

Location: Aarti Green Tech Ltd., Rohtak

Reporting To: Plant Head / Head – Operations & Maintenance

Experience: 8–12 years, preferably in steel recycling, heavy engineering, metal processing, manufacturing or similar continuous-process industry

1. Job Purpose To lead and manage the complete mechanical maintenance function of the plant, ensuring high equipment availability, reliability and safe operation through effective maintenance planning, preventive and predictive maintenance, timely breakdown response, spare-parts planning and systematic improvement of equipment performance.

The position will be responsible for maintenance of shredder systems, baling presses, material handling equipment (MHEs), cranes and other mechanical equipment installed across the plant.

2. Key Responsibilities

A. Maintenance Planning & Scheduling

- Prepare and implement annual, monthly, weekly and daily mechanical maintenance plans .
- Develop preventive and predictive maintenance schedules for all critical equipment.
- Plan and coordinate planned shutdowns and major maintenance activities .
- Ensure maintenance activities are completed within the planned time with minimum production disruption.
- Develop equipment-wise maintenance checklists, maintenance standards and job plans.
- Maintain equipment history and maintenance records through the CMMS/Maintenance Management System.

B. Shredder & Baling Press Maintenance

- Take overall responsibility for the mechanical maintenance of shredder machines, feeding systems, conveyors, discharge systems, sorting systems and associated equipment .
- Manage maintenance of baling presses , hydraulic systems, cylinders, pumps, valves, piping and associated mechanical systems.
- Monitor critical components such as bearings, gearboxes, couplings, shafts, rotors, knives/blades, hydraulic systems, belts, chains and structural components.
- Analyse recurring failures and implement permanent corrective actions.
- Coordinate with OEM/service agencies for major repairs, inspections and technical support.

C. MHE & Material Handling Equipment Maintenance

- Ensure reliable maintenance of all MHEs, including:
- Wheel loaders/pay-loaders
- Sennebogen/material handlers
- SANY equipment
- Farana/mobile cranes
- JCB and other material handling equipment
- EOT cranes
- Develop equipment-wise preventive maintenance schedules based on running hours, OEM recommendations and equipment condition .
- Monitor equipment availability, breakdown frequency, maintenance cost and recurring problems.

D. Breakdown Maintenance

- Lead the team for quick and effective response to mechanical breakdowns.
- Ensure root cause analysis (RCA) of major and repetitive breakdowns.




- Establish corrective and preventive actions to minimise recurrence.
- Maintain breakdown history and analyse MTBF, MTTR and equipment downtime .
- Ensure availability of critical manpower, tools, consumables and spares for emergency maintenance.

E. Spare Parts Planning & Inventory

- Prepare annual and monthly spare-parts requirements based on equipment criticality and maintenance plans.
- Identify and maintain a list of critical, insurance and fast-moving spares .
- Establish minimum/maximum stock levels and reorder levels for critical mechanical spares.
- Review spare consumption and identify opportunities to reduce maintenance cost.
- Coordinate with Stores and Procurement for timely availability of critical spares.
- Standardise spares wherever technically feasible and avoid unnecessary inventory.
- Maintain proper records of spare consumption against equipment and maintenance jobs.

F. Preventive & Predictive Maintenance

- Implement condition-based maintenance practices wherever feasible.
- Monitor equipment health through:
- Vibration monitoring
- Temperature monitoring
- Lubrication/oil analysis
- Hydraulic oil condition
- Alignment and balancing
- Visual and dimensional inspections
- Identify early warning signs of equipment failure and plan corrective action before breakdown.

G. Maintenance Team Management

- Lead, guide and develop the mechanical maintenance team, including engineers, supervisors, fitters, technicians, riggers and contract manpower.
- Allocate manpower according to equipment priority and shift requirements.
- Develop skill matrices and conduct technical training for the maintenance team.
- Ensure proper shift handover and maintenance communication.
- Monitor overtime and manpower utilisation.

H. Safety & Compliance

- Ensure all maintenance activities are carried out in accordance with plant safety procedures and statutory requirements .
- Strictly implement LOTO, work permits, isolation procedures and safe maintenance practices.
- Ensure proper use of PPE and safe working practices during maintenance, lifting and hot-work activities.
- Ensure periodic inspection and maintenance of cranes, lifting equipment and other safety-critical equipment.
- Participate in incident investigations and implement corrective actions.

I. Maintenance Cost & Performance Improvement

- Prepare and monitor the mechanical maintenance budget.




- Control maintenance cost without compromising equipment reliability and safety.
- Identify opportunities for cost reduction, energy efficiency and equipment life improvement .
- Evaluate repair-versus-replacement decisions for major components.
- Drive initiatives for improving equipment reliability and reducing unplanned downtime.

J. Projects & Technical Support

- Provide mechanical inputs for new equipment installation, modification and expansion projects.
- Review technical specifications of mechanical equipment and spares.
- Coordinate with OEMs, contractors and service providers for installation, commissioning and major repairs.
- Ensure proper commissioning and handover of new equipment to the maintenance team.

3. Key Equipment Exposure The candidate should preferably have hands-on experience in maintenance of some/all of the following:

- Industrial shredders and shredding systems
- Baling presses
- Hydraulic power packs and hydraulic systems
- Conveyors and material handling systems
- Gearboxes, bearings, couplings and shafts
- Heavy-duty rotating equipment
- EOT cranes and lifting equipment
- Mobile cranes
- Excavators and material handlers
- Wheel loaders/pay-loaders
- JCB/SANY/Sennebogen or similar MHEs
- Pneumatic systems
- Lubrication systems
- Structural and fabrication-related maintenance

4. Required Skills & Competencies

- Strong knowledge of mechanical maintenance and maintenance planning
- Good understanding of hydraulic and mechanical systems
- Strong troubleshooting and breakdown-analysis capability
- Knowledge of RCA, FMEA, MTBF, MTTR and preventive maintenance
- Good spare-parts planning and inventory management skills
- Ability to manage maintenance contractors and OEM service agencies
- Strong team leadership and manpower planning capability
- Good analytical and problem-solving skills
- Ability to work under pressure in a continuous-process manufacturing workplace
- Good knowledge of maintenance documentation and MIS
- Working knowledge of CMMS/SAP or similar maintenance management systems will be preferred.

5. Qualification B.E. / B.Tech. in Mechanical Engineering from a recognised institution.

Preferred:

Experience in heavy engineering, steel, metal recycling, manufacturing, shredding, material handling or similar industrial operations.

6. Key Performance Indicators (KPIs)

- Mechanical equipment availability
- Reduction in unplanned breakdowns
- Reduction in equipment downtime
- Improvement in MTBF
- Reduction in MTTR
- Preventive maintenance compliance
- Critical spare availability
- Maintenance cost per unit/ton
- Reduction in repeat breakdowns
- Shutdown maintenance effectiveness
- Safety performance / zero maintenance-related incidents
- MHE availability and reliability
- Shredder and baling press uptime

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