To lead and manage all mechanical, electrical, instrumentation, utility, and preventive maintenance activities in the metal packaging and printing plant, ensuring maximum machine availability, minimum breakdowns, safe operation, and uninterrupted production.

Key Roles & Responsibilities

A. Machine & Equipment Maintenance

- Manage maintenance of metal printing, coating, slitting, shearing, stamping, forming, can-making, and packing machinery.
- Maintain sheet-fed offset printing machines, coating/varnishing machines, curing ovens, compressors, hydraulic and pneumatic systems.
- Ensure proper maintenance of body-making, can-making, seaming, punching, forming, and other production equipment, as applicable.
- Monitor machine condition and identify potential failures before breakdowns.
- Ensure timely repair and restoration of production equipment.

B. Preventive & Predictive Maintenance
- Develop and implement Preventive Maintenance (PM) schedules for all critical machines.
- Plan predictive maintenance activities such as vibration monitoring, temperature checks, lubrication checks, electrical testing, etc.
- Maintain equipment history, maintenance records, and breakdown analysis.
- Review PM effectiveness and continuously improve maintenance practices.

C. Breakdown Maintenance
- Lead the maintenance team during machine breakdowns and emergency situations.
- Analyze breakdown causes and implement Root Cause Analysis (RCA) and corrective actions.
- Reduce machine downtime and improve MTBF and MTTR.
- Coordinate with production to prioritize critical breakdowns.

D. Electrical & Automation Maintenance
- Manage maintenance of HT/LT electrical systems, MCC panels, control panels, motors, drives, PLCs, sensors, and control systems.
- Ensure proper functioning of PLC-based production equipment and automation systems.
- Coordinate troubleshooting of electrical and instrumentation problems.
- Ensure electrical safety, earthing, protection systems, and statutory compliance.

E. Printing Machine Maintenance
- Ensure regular maintenance of offset printing machines.




- Monitor printing machine components such as inking systems, dampening systems, cylinders, rollers, blankets, dryers/curing systems, and drive systems.
- Coordinate with OEM/service engineers for specialized machine maintenance.
- Maintain machine accuracy and performance to support consistent print quality.

F. Utilities & Facility Maintenance
- Manage maintenance of:
- Air compressors
- DG sets
- Chillers
- HVAC systems
- Cooling systems
- Air dryers
- Water systems
- Pumps
- Electrical distribution systems
- Fire-fighting systems
- Plant infrastructure
- Ensure uninterrupted availability of essential utilities for production.

G. Spare Parts & Inventory
- Identify and maintain adequate stock of critical maintenance spares.
- Control consumption of spare parts and maintenance materials.
- Coordinate with Stores and Purchase for timely procurement.
- Develop a list of critical and long-lead-time spare parts.

H. Safety & Compliance
- Ensure maintenance activities are carried out according to plant safety procedures.
- Implement Lockout/Tagout (LOTO) procedures during maintenance.
- Ensure proper use of PPE by maintenance personnel.
- Ensure compliance with electrical, fire, pressure vessel, lifting equipment, and other applicable statutory requirements.
- Conduct safety inspections and close maintenance-related observations.

I. Team Management
- Lead and supervise Mechanical, Electrical, Instrumentation, and Utility maintenance teams.
- Allocate manpower and maintenance activities according to production requirements.
- Conduct training and skill development programs for maintenance personnel.
- Evaluate employee performance and identify training requirements.
- Maintain proper shift-wise handover and communication.

J.



Cost & Energy Control
- Prepare and control the maintenance budget.
- Monitor maintenance costs, spare consumption, and external service expenses.
- Identify opportunities to reduce energy consumption, breakdown costs, and maintenance costs.
- Implement energy-saving and efficiency improvement projects.

K. Documentation & Reporting
- Maintain:
- Preventive maintenance records
- Breakdown reports
- Machine history cards
- Spare inventory records
- Maintenance checklists
- Calibration records
- Utility records
- RCA reports
- Maintenance KPI reports
- Prepare daily, weekly, and monthly maintenance reports for management.

Key Skills & Competencies
- Strong knowledge of metal packaging manufacturing equipment.
- Good knowledge of offset printing and metal sheet printing machinery.
- Knowledge of mechanical, electrical, PLC, pneumatic, hydraulic, and instrumentation systems.
- Strong troubleshooting and root-cause-analysis skills.
- Knowledge of preventive and predictive maintenance.
- Knowledge of TPM, 5S, Kaizen, RCA, MTBF, and MTTR.
- Good leadership and team-management skills.
- Ability to coordinate effectively with Production, Quality, Stores, Purchase, and EHS departments.

Educational Qualification Diploma / B.E. / B.Tech in Mechanical or related Engineering discipline.

Experience

8–15 years of relevant maintenance experience, preferably in metal packaging, tinplate printing, metal can manufacturing, sheet-fed offset printing, or similar manufacturing industries, with supervisory/managerial experience.

Key Performance Indicators (KPIs)

- Machine availability %
- Breakdown hours
- MTBF – Mean Time Between Failures
- MTTR – Mean Time To Repair
- Preventive maintenance compliance %
- Production downtime
- Maintenance cost
- Spare-parts consumption
- Utility availability
- Energy consumption
- Repeat breakdown percentage
- Safety compliance
- Completion of maintenance improvement projects

Pay: ₹40,000.00 - ₹60,000.00 per month

Perks

- Provident Fund

Work Location: In person

📌 Assistant Manager Maintenance (Udupi)
🏢 GPPL
📍 Udupi