– PLANT MAINTENANCE MECHANICAL MANAGER

Position Overview

- Responsible for overall mechanical maintenance of the manufacturing plant.
- Responsible for preventive, predictive and breakdown maintenance activities.
- Ensure maximum availability and reliability of production machinery.
- Minimize machine breakdowns and production downtime.
- Manage maintenance activities for fabrication, material handling and GI/Hot-Dip Galvanizing plant equipment.
- Ensure safe and efficient operation of all mechanical equipment.
- Coordinate with Production, Electrical, Instrumentation, Quality, Safety, Stores and Purchase departments.
- Lead mechanical maintenance engineers, supervisors, technicians, fitters and maintenance contractors.

Key Responsibilities

EOT Crane Maintenance

- Maintain and service EOT cranes up to 50 Tons capacity.
- Conduct regular inspection and preventive maintenance of EOT cranes.
- Maintain gearboxes, couplings, bearings, shafts, wheels and brakes.
- Inspect hooks, hook blocks, wire ropes and drums.
- Monitor abnormal noise, vibration, heating and lubrication.
- Troubleshoot crane mechanical breakdowns.
- Coordinate with Electrical Maintenance for electrical/control-related crane issues.
- Maintain crane maintenance history and inspection records.
- Coordinate periodic inspection and testing as applicable.
- Maintain Goliath cranes up to 30 Tons capacity.
- Inspect crane structure, wheels, rails, gearboxes and couplings.
- Maintain brakes, bearings, shafts, hooks and wire ropes.
- Monitor crane travel alignment.
- Carry out lubrication and replacement of worn components.
- Coordinate crane inspection and load testing as applicable.
- Maintain power presses up to 150 Tons capacity.
- Conduct preventive and breakdown maintenance.
- Maintain flywheel, clutch, brake, crankshaft and connecting rods.
- Maintain bearings, ram and slide mechanisms.
- Ensure proper lubrication.
- Check machine alignment and vibration.
- Troubleshoot mechanical failures.
- Ensure safe isolation before maintenance.
- Maintain hydraulic presses up to 500 Tons capacity.
- Maintain hydraulic pumps, cylinders, valves and power packs.
- Inspect hydraulic hoses, pipes, filters and oil tanks.
- Monitor hydraulic pressure and oil temperature.
- Identify hydraulic leakage and pressure-loss problems.
- Troubleshoot slow operation and cylinder malfunction.
- Maintain hydraulic oil quality and cleanliness.
- Replace worn seals, hoses, valves and hydraulic components.
- Maintain hydraulic shearing machines for material thickness up to 20 mm.
- Maintain hydraulic pumps, cylinders, valves and mechanical systems.
- Check blade condition and alignment.
- Maintain blade clearance and cutting accuracy.
- Troubleshoot hydraulic and mechanical problems.
- Conduct preventive maintenance as per schedule.
- Replace worn blades and mechanical components.
- Maintain cold forming machines and associated mechanical systems.
- Maintain rollers, shafts, bearings and gearboxes.
- Maintain couplings, chains and drive systems.
- Maintain hydraulic and pneumatic systems.
- Check machine alignment.
- Monitor vibration and abnormal noise.
- Troubleshoot forming and mechanical problems.
- Recommend machine modifications for reliability improvement.
- Maintain CNC drilling machines used for structural steel fabrication.
- Maintain spindle systems, bearings and gearboxes.
- Maintain feed mechanisms and drive systems.
- Maintain hydraulic and pneumatic systems.
- Maintain coolant systems.
- Check machine alignment and drilling accuracy.
- Coordinate with CNC/electrical technicians for control-related issues.
- Carry out preventive maintenance and troubleshooting.
- Maintain oxy-fuel cutting machines.
- Maintain machine movement and drive mechanisms.
- Inspect guide rails, wheels and mechanical assemblies.
- Ensure smooth machine movement.
- Maintain alignment and positioning systems.
- Replace worn mechanical components.
- Coordinate with Safety and Production for safe maintenance activities.
- Maintain beam straightening machines for material up to approximately 50 mm thickness, as applicable to installed equipment.
- Maintain hydraulic cylinders, rollers, shafts and bearings.
- Check roller alignment and machine condition.
- Maintain hydraulic pressure.
- Troubleshoot straightening inaccuracies.
- Maintain machine settings and calibration requirements.
- Conduct preventive maintenance.
- Reduce recurring breakdowns and dimensional issues.
- Maintain SAW welding machines used for large poles and structural steel fabrication.
- Maintain welding heads and wire-feed mechanisms.
- Maintain welding carriage and drive systems.
- Maintain gearboxes, bearings and couplings.
- Maintain hydraulic and pneumatic systems.
- Check welding-machine mechanical alignment.
- Troubleshoot wire-feed and carriage movement problems.
- Coordinate with Welding, Electrical and Quality teams.
- Support consistent welding performance.
- Take responsibility for mechanical maintenance of the complete GI/Hot-Dip Galvanizing plant.
- Prepare preventive-maintenance schedules for GI plant equipment.
- Minimize GI plant mechanical breakdowns.
- Maintain critical equipment and spare parts.
- Monitor equipment reliability and maintenance cost.




- Maintain mechanical equipment associated with degreasing tanks.
- Maintain pickling tank mechanical systems.
- Maintain rinsing tank equipment.
- Maintain fluxing tank equipment.
- Maintain pumps, valves and pipelines.
- Maintain agitators and circulation systems.
- Check leakage, corrosion and mechanical deterioration.
- Ensure reliable operation of material-handling systems.
- Maintain flux circulation systems.
- Maintain flux pumps and associated mechanical components.
- Maintain valves, pipelines and filters.
- Inspect mechanical seals and bearings.
- Monitor vibration and leakage.
- Carry out preventive maintenance of flux equipment.
- Maintain mechanical systems associated with galvanizing kettle operations.
- Inspect kettle support arrangements.
- Maintain kettle lifting and handling systems where applicable.
- Inspect associated mechanical structures and supports.
- Monitor mechanical deterioration and abnormal vibration.
- Coordinate maintenance activities with Production and EHS teams.
- Ensure maintenance activities do not compromise plant safety.
- Maintain cranes and hoists used in GI operations.
- Maintain lifting equipment and handling fixtures.
- Maintain trolleys and transfer mechanisms.
- Maintain conveyors and material-transfer systems where installed.
- Inspect hooks, chains, lifting devices and mechanical components.
- Ensure smooth and safe movement of galvanized components.
- Coordinate inspection/testing requirements with competent teams.
- Maintain zinc ash handling equipment.
- Maintain zinc dross handling systems.
- Maintain conveyors, bins and transfer mechanisms where installed.
- Inspect mechanical drives and bearings.
- Maintain lifting and material-handling systems.
- Minimize breakdowns during zinc recovery/handling operations.
- Maintain mechanical components of quenching systems.
- Maintain cooling-water pumps.
- Maintain pipelines, valves and tanks.
- Inspect mechanical seals, bearings and couplings.
- Monitor leakage and abnormal vibration.
- Ensure reliable circulation and cooling operation.
- Maintain process pumps used in GI operations.
- Maintain centrifugal and other installed process pumps.
- Maintain mechanical seals and bearings.
- Maintain couplings and pump alignment.
- Inspect pipelines, valves, flanges and joints.
- Monitor leakage and vibration.
- Maintain critical pump spares.
- Conduct preventive maintenance to avoid process interruption.
- Maintain mechanical components of GI exhaust systems.
- Maintain exhaust fans and blowers.
- Maintain bearings, belts and couplings.
- Inspect ducting and mechanical supports.
- Monitor vibration and abnormal noise.
- Coordinate with EHS regarding ventilation requirements.
- Ensure planned maintenance of ventilation equipment.
- Maintain mechanical components of galvanizing/heating furnace systems where applicable.
- Maintain furnace doors and mechanical mechanisms.
- Maintain rollers, chains and drive systems.
- Maintain bearings and mechanical supports.
- Maintain exhaust mechanisms, blowers and dampers.
- Coordinate with Electrical, Instrumentation and Process teams.
- Ensure safe maintenance and isolation procedures.
- Prepare annual preventive-maintenance plans.
- Prepare monthly and weekly maintenance schedules.
- Prepare machine-wise maintenance checklists.
- Ensure timely completion of preventive maintenance.
- Monitor overdue maintenance activities.
- Maintain equipment history cards.
- Identify critical equipment.
- Develop equipment-specific maintenance standards.
- Analyze recurring failures.
- Improve preventive-maintenance frequency based on equipment condition.
- Attend major equipment breakdowns immediately.
- Diagnose mechanical failures.
- Coordinate with Electrical and Instrumentation teams.
- Identify root cause of breakdown.
- Arrange required manpower and spare parts.
- Restore equipment safely and efficiently.
- Record breakdown duration.
- Record parts replaced.
- Record root cause.
- Record corrective action.
- Implement permanent corrective actions for repeated failures.
- Monitor equipment vibration.
- Monitor bearing temperature.
- Monitor gearbox condition.
- Monitor hydraulic oil condition.
- Monitor lubrication condition.
- Monitor abnormal noise.
- Monitor equipment alignment.
- Identify early signs of equipment failure.
- Recommend condition-based maintenance where appropriate.
- Use maintenance history to predict recurring failures.
- Prepare equipment-wise lubrication schedules.
- Identify lubrication points.
- Specify correct lubricant/grease as per OEM/site standard.
- Monitor lubrication frequency.
- Maintain gearbox oil levels.
- Monitor hydraulic oil condition.
- Maintain bearing lubrication.
- Maintain chain and drive lubrication.
- Prevent over-lubrication and under-lubrication.
- Maintain lubrication records.
- Prepare critical spare-parts lists.
- Maintain minimum and maximum stock levels.
- Identify critical mechanical components.




- Coordinate with Stores and Purchase.
- Verify technical specifications before procurement.
- Monitor spare consumption.
- Identify slow-moving and obsolete spares.
- Maintain emergency spares for critical equipment.
- Control maintenance inventory cost.
- Prepare planned shutdown maintenance schedules.
- Coordinate shutdown requirements with Production.
- Prepare manpower requirements.
- Prepare spare-parts requirements.
- Prepare equipment-wise job lists.
- Allocate maintenance responsibilities.
- Monitor shutdown progress.
- Conduct pre-start inspection.
- Coordinate safe equipment restart.
- Prepare shutdown completion report.
- Ensure compliance with plant safety procedures.
- Follow Lockout/Tagout (LOTO) requirements.
- Ensure proper equipment isolation.
- Follow Permit-to-Work requirements.
- Ensure safe hydraulic pressure isolation.
- Control stored mechanical energy.
- Ensure safe lifting practices.
- Ensure PPE compliance.
- Ensure barricading during maintenance.
- Coordinate with EHS/Safety Department.
- Ensure safe working at height.
- Ensure safe maintenance in GI chemical/process areas.

Team Management
- Lead Mechanical Maintenance Engineers.
- Lead Maintenance Supervisors.
- Manage Fitters and Technicians.
- Allocate daily maintenance activities.
- Conduct maintenance review meetings.
- Monitor team productivity.
- Develop technician skills.
- Conduct technical training.
- Evaluate maintenance contractor performance.
- Maintain discipline and housekeeping in maintenance areas.

Contractor Management
- Manage mechanical maintenance contractors.
- Define scope of work.
- Verify contractor competency.
- Ensure safety induction.
- Ensure required PPE.
- Ensure work permits.
- Monitor quality of maintenance work.
- Monitor contractor manpower.
- Verify completion of work.
- Evaluate contractor performance.
- Maintain contractor maintenance records.

Root Cause Analysis & Improvement
- Conduct RCA for repeated breakdowns.
- Conduct 5 Why analysis.
- Conduct Fishbone analysis where appropriate.
- Analyze equipment failure trends.
- Identify chronic equipment problems.
- Recommend equipment modifications.
- Improve machine reliability.
- Reduce maintenance cost.
- Reduce production downtime.
- Improve MTBF.
- Reduce MTTR.

Maintenance Documentation
- Maintain equipment master list.
- Maintain preventive-maintenance schedules.
- Maintain breakdown register.
- Maintain equipment history cards.
- Maintain lubrication records.
- Maintain spare-parts records.
- Maintain crane maintenance records.
- Maintain hydraulic equipment records.
- Maintain GI plant maintenance records.
- Maintain shutdown reports.
- Maintain RCA reports.
- Maintain CAPA records.
- Maintain contractor maintenance records.

Maintenance KPI
- Machine availability.
- Equipment uptime.
- Breakdown hours.
- Breakdown frequency.
- MTBF.
- MTTR.
- Preventive-maintenance compliance.
- Repeat breakdown percentage.
- Maintenance cost.
- Spare-parts consumption.
- Critical equipment availability.
- Shutdown completion percentage.
- Emergency breakdown response time.
- GI plant equipment availability.

Qualifications
- Bachelor's Degree in Mechanical Engineering or equivalent.
- Diploma in Mechanical Engineering may be considered based on relevant experience and company requirements.
- 10–15 years of relevant plant maintenance experience preferred.
- Robust experience in heavy engineering/steel fabrication plant maintenance.
- Experience in GI/Hot-Dip Galvanizing Plant Maintenance preferred.
- Strong hands-on mechanical maintenance experience.
- Experience in managing maintenance teams and contractors.

Technical Skills
- EOT Crane Maintenance.
- Goliath Crane Maintenance.
- Hydraulic Press Maintenance.
- Power Press Maintenance.
- Hydraulic Shearing Machine Maintenance.
- Cold Forming Machine Maintenance.
- CNC Drill Machine Maintenance.
- Oxy-Fuel Cutting Machine Maintenance.
- Beam Straightening Machine Maintenance.
- SAW Welding Machine Maintenance.
- GI/Hot-Dip Galvanizing Plant Maintenance.
- Hydraulic Systems.
- Pneumatic Systems.
- Gearboxes.
- Pumps.
- Bearings.
- Couplings.
- Shafts.
- Mechanical Drives.
- Lubrication Systems.
- Material Handling Systems.
- Preventive Maintenance.
- Breakdown Maintenance.
- Predictive Maintenance.
- Root Cause Analysis.

Behavioural Competencies
- Strong leadership skills.
- Strong problem-solving ability.
- Good decision-making skills.
- Analytical thinking.
- Team management capability.
- Maintenance planning ability.
- Good communication skills.
- Contractor management skills.
- Production coordination.
- Safety-oriented approach.
- Cost-conscious approach.
- Ability to work under pressure.
- Continuous improvement mindset.

Key Deliverables
- Maximum equipment availability.
- Minimum unplanned breakdowns.
- Improved preventive-maintenance compliance.
- Reduced repeat breakdowns.
- Improved GI plant reliability.
- Reduced maintenance cost.
- Effective critical-spare management.
- Safe maintenance execution.
- Timely shutdown completion.
- Accurate maintenance documentation.
- Improved MTBF.
- Reduced MTTR.
- Improved production equipment reliability.
- Continuous improvement in plant maintenance performance.

Pay: ₹60,000.00 - ₹80,000.00 per month

Work Location: In person

📌 Maintenance Manager (Bhilai)
🏢 SALASAR TECHNO ENGINEERING
📍 Bhilai