JOB DESCRIPTION – MECHANICAL HEAD OF DEPARTMENTDRI / SPONGE IRON PLANT

Designation: Head of Department – Mechanical
Department: Mechanical Maintenance
Plant: DRI / Sponge Iron Plant
Reporting To: Plant Head / General Manager
Location: Plant Site

1. JOB PURPOSE

To lead and manage the complete Mechanical Maintenance function of the DRI Plant and ensure high equipment availability, reliability, safety, and optimum maintenance cost.

The Mechanical HOD will be responsible for preventive, predictive, breakdown, shutdown, and project maintenance of all mechanical equipment associated with the DRI plant.

2. KEY RESPONSIBILITIESA. DRI Plant Mechanical Maintenance

- Overall responsibility for mechanical maintenance of the DRI/Sponge Iron Plant.
- Ensure maximum availability and reliability of plant equipment.
- Plan and execute preventive, predictive, corrective, and breakdown maintenance.
- Monitor equipment health and identify potential failures in advance.
- Reduce mechanical breakdowns, downtime, and production losses.
- Ensure proper maintenance history and equipment records.

B. Rotary Kiln & Cooler

- Ensure reliable operation and maintenance of Rotary Kiln and Cooler systems.
- Monitor kiln supporting systems, girth gear, pinion, rollers, bearings, seals, drive systems, and lubrication systems.
- Monitor alignment, vibration, temperature, lubrication, and mechanical condition of critical equipment.
- Plan inspection and maintenance of kiln internals and associated equipment during shutdown.
- Coordinate with Operations for kiln-related mechanical issues.

C. Material Handling Equipment

Ensure maintenance of:

- Raw material feeding systems
- Belt conveyors
- Bucket elevators
- Apron feeders
- Screw conveyors
- Vibrating feeders
- Crushers
- Screens
- Transfer points
- Hoppers and chutes
- Product and char handling systems

D. Fans, Pumps & Utilities

- Ensure proper maintenance of ID fans, FD fans, cooling fans, blowers, and other rotating equipment.
- Supervise maintenance of process and utility pumps.
- Monitor bearings, couplings, shafts, impellers, mechanical seals, and lubrication systems.
- Ensure proper alignment and balancing of rotating equipment.

E. Breakdown Maintenance

- Lead the Mechanical team during critical and emergency breakdowns.
- Ensure quick identification of failure and restoration of equipment.
- Conduct Root Cause Analysis (RCA) for major and repeated failures.
- Implement permanent corrective and preventive actions.
- Maintain breakdown history and analyze recurring problems.

F. Preventive & Predictive Maintenance

- Prepare and implement preventive maintenance schedules.




- Ensure 100% compliance with planned maintenance activities.
- Establish inspection routines for critical equipment.
- Monitor vibration, temperature, lubrication, alignment, and other equipment health parameters.
- Develop condition-based maintenance practices wherever applicable.

G. Shutdown Maintenance

- Prepare monthly/quarterly/annual shutdown maintenance plans.
- Identify critical jobs before shutdown.
- Prepare manpower, tools, spares, consumables, and contractor requirements.
- Monitor shutdown activities and ensure completion within the planned time.
- Conduct post-shutdown inspection and equipment trial runs.

H. Manpower Management

- Lead Mechanical Engineers, Shift In-charges, Supervisors, Technicians, Fitters, Welders, Helpers, and contract manpower.
- Prepare manpower deployment and shift schedules.
- Assign jobs according to employee skill and plant requirements.
- Monitor performance and discipline of the maintenance team.
- Conduct training and skill-development programs.

I. Spare Parts Management

- Identify critical mechanical spares for DRI plant equipment.
- Maintain minimum/maximum stock levels.
- Coordinate with Stores and Purchase departments.
- Ensure timely procurement of critical spares.
- Control spare consumption and maintenance expenditure.
- Maintain proper records of critical equipment spares.

J. Safety Management

- Ensure strict compliance with plant safety procedures.
- Implement LOTO before maintenance activities.
- Ensure proper PPE and safe working practices.
- Conduct toolbox meetings and safety inspections.
- Ensure safe execution of height work, confined-space work, hot work, lifting operations, and heavy equipment maintenance.
- Investigate mechanical maintenance-related incidents and implement corrective actions.

K. Cost Control & Budget

- Prepare the Mechanical Maintenance annual budget.
- Control maintenance expenditure without compromising safety and reliability.
- Reduce breakdown and emergency maintenance costs.
- Optimize manpower, spares, consumables, and contractor utilization.
- Identify opportunities for maintenance cost reduction.

L. Project & Modification Work

- Review mechanical requirements for plant expansion, modification, and improvement projects.
- Supervise installation, erection, commissioning, and trial runs of new mechanical equipment.




- Coordinate with Engineering, Projects, Production, Electrical, and Instrumentation departments.
- Ensure proper handover of newly installed equipment to Maintenance.

3. KEY EQUIPMENT RESPONSIBILITY

The Mechanical HOD should have strong working knowledge of:

- Rotary Kiln
- Kiln Drive & Gearbox
- Girth Gear & Pinion
- Kiln Rollers & Bearings
- Cooler
- ID/FD Fans
- Blowers
- Crushers
- Screens
- Vibrating Feeders
- Belt Conveyors
- Bucket Elevators
- Screw Conveyors
- Pumps
- Gearboxes
- Couplings
- Bearings
- Hydraulic & Pneumatic Systems
- Lubrication Systems
- Hoppers, Chutes & Gates
- Material Handling Systems
- Structural and mechanical maintenance equipment

4. KEY PERFORMANCE INDICATORS (KPIs)

- Mechanical equipment availability
- Reduction in breakdown hours
- Reduction in repeat breakdowns
- Improvement in MTBF
- Reduction in MTTR
- Preventive Maintenance Compliance
- Shutdown completion within planned time
- Reduction in maintenance cost
- Critical spare availability
- Reduction in production loss due to mechanical failures
- Safety compliance and zero major maintenance accidents

5. QUALIFICATION

Essential:

- B.E./B.Tech/Diploma in Mechanical Engineering.

Preferred:

- Experience in DRI/Sponge Iron/Steel Plant mechanical maintenance.

6. EXPERIENCE

- 10–15+ years of experience in mechanical maintenance.
- Preferably 5+ years in a senior management/leadership role in a DRI/Sponge Iron or Steel Plant.
- Strong experience in Rotary Kiln, Cooler, Material Handling, Fans, Pumps, Gearboxes, Conveyors, and shutdown maintenance.

7. REQUIRED SKILLS

- Robust knowledge of DRI plant mechanical equipment
- Mechanical troubleshooting and breakdown analysis
- Preventive and predictive maintenance
- Root Cause Analysis
- Shutdown planning and execution
- Team leadership and manpower management
- Spare parts and inventory management
- Maintenance budgeting and cost control
- Safety management
- Good communication and coordination skills
- MS Office / Excel and maintenance reporting

8. AUTHORITY & ACCOUNTABILITY

The Mechanical HOD will be accountable for the overall performance of the Mechanical Maintenance Department, including equipment reliability, plant availability, breakdown control, preventive maintenance, shutdown execution, manpower productivity, spare management, maintenance cost, and safety compliance.

Prepared By: HR Department
Reviewed By: Plant Head
Approved By: Management
Department: Mechanical Maintenance
Plant: DRI / Sponge Iron Plant

Pay: ₹50,000.00 - ₹80,000.00 per month

Benefits:

- Leave encashment

Work Location: In person

📌 Mechanical HOD (SID) (India)
🏢 SHIV SHAKTI STEEL PRIVATE
📍 India