Mechanical Maintenance Incharge

Title Mechanical Maintenance Incharge

Preferred Companies from Automobile or Engineering Industry

Job Location Coimbatore Tamilnadu

Essential LanguagesTamil (Read, Write, Speak); English (Read, Write, Speak)

Organisation Chart:

Plant Head

Mechanical Maintenance Incharge

Shift Supervisors

Helper

Job Purpose

The Mechanical Maintenance Incharge is responsible for leading and managing the mechanical maintenance function at Unit-IV, Karumathampatti, Coimbatore. The role ensures maximum equipment availability, reliability, and performance through effective people management, manufacturing improvements, system implementation, cost effectiveness, and a relentless focus on achieving zero accidents.

The incumbent will drive preventive, predictive, and breakdown maintenance strategies while fostering a culture of continuous improvement, safety, and operational excellence.

Key Responsibilities

1. People Management

- Lead, mentor, and develop the mechanical maintenance team, including Shift Supervisors and Helpers.
- Allocate manpower effectively across shifts to ensure uninterrupted maintenance coverage.
- Conduct regular training needs analysis and skill development programs for team members.
- Foster a positive work culture, discipline, and high morale within the maintenance function.
- Set clear performance expectations, conduct periodic reviews, and provide constructive feedback.

1. Manufacturing Improvements

- Drive continuous improvement initiatives to enhance equipment reliability, availability, and overall plant efficiency.
- Analyse recurring breakdowns and implement root cause corrective and preventive actions (RCCPA).
- Optimise maintenance schedules, spares consumption, and repair methodologies to reduce downtime.
- Collaborate with production and quality teams to improve Overall Equipment Effectiveness (OEE).
- Implement reliability-centred maintenance (RCM) and total productive maintenance (TPM) practices.

1. System Implementation

- Establish and maintain robust maintenance management systems, including CMMS (Computerised Maintenance Management System).
- Ensure adherence to standard operating procedures (SOPs), work instructions,



and maintenance checklists.
- Maintain accurate records of maintenance activities, equipment history, and spares inventory.
- Implement and sustain 5S, Kaizen, and other lean manufacturing systems within the maintenance function.
- Ensure compliance with statutory, environmental, and safety management systems.

1. Cost Effectiveness

- Prepare and manage the mechanical maintenance budget, ensuring optimal utilisation of resources.
- Control spares and consumables inventory to minimise carrying costs while ensuring availability.
- Identify and implement cost-reduction opportunities without compromising equipment reliability or safety.
- Evaluate vendor performance and negotiate contracts for external maintenance services.
- Monitor and report key maintenance KPIs, including MTBF, MTTR, and maintenance cost per tonne.

1. Zero Accident

- Champion a strong safety culture with the goal of zero accidents and zero harm.
- Ensure strict adherence to safety protocols, permit-to-work systems, and lockout/tagout procedures.
- Conduct regular safety audits, risk assessments, and toolbox talks for the maintenance team.
- Investigate and report all incidents, near misses, and unsafe conditions, implementing corrective actions.
- Ensure all maintenance activities comply with applicable safety regulations and company policies.

(E) Key Performance Indicators (KPIs)

- Equipment Availability and Reliability (MTBF, MTTR)
- Overall Equipment Effectiveness (OEE) improvement
- Reduction in Breakdown Frequency and Downtime
- Maintenance Cost per Unit of Production
- Spares Inventory Turnover and Cost Control
- Adherence to Preventive Maintenance Schedule
- Safety Incident Rate (Target: Zero Accidents)
- Team Productivity and Skill Development Metrics
- CMMS Data Accuracy and Compliance




- Implementation of Continuous Improvement Projects

Qualifications and Experience

Criteria Requirement

Educational Qualification

Bachelor's Degree in Mechanical Engineering (B.E. / B.Tech) or equivalent

Total Experience

18-25+ years of relevant experience in mechanical maintenance

Industry Experience Automobile or Engineering Industry preferred

Functional Experience Hands-on experience in preventive, predictive, and breakdown maintenance of heavy machinery and equipment

Leadership Experience Proven track record of leading maintenance teams in a manufacturing environment

Technical Expertise Solid knowledge of hydraulics, pneumatics, rotating equipment, conveyors, crushers, mixers, and utility systems

Systems Knowledge Proficiency in CMMS, TPM, RCM, 5S, Kaizen, and lean maintenance practices

Safety Knowledge Thorough understanding of industrial safety standards, permit-to-work systems, and statutory compliance

(G) Competencies

Behavioural Competencies:

- Leadership and People Management
- Decision Making and Problem Solving
- Communication and Interpersonal Skills
- Ownership and Accountability
- Safety Orientation
- Cost Consciousness
- Change Management

Technical Competencies:

- Mechanical Maintenance Management
- Reliability Engineering
- Root Cause Analysis (RCA)
- CMMS and Maintenance Planning
- Spare Parts Management
- Budgeting and Cost Control
- Safety and Statutory Compliance

(H) Working Conditions

- Work Workplace: Manufacturing plant environment with exposure to heavy machinery, noise, heat, and dust.
- Work Schedule: General shift with flexibility to work extended hours, shifts, or weekends as required to meet maintenance and production needs.
- Travel: Minimal; occasional travel for vendor visits or training may be required.
- Physical Requirements: Ability to walk through the plant, climb ladders, and inspect equipment as needed.

(I) Reporting Structure

- Reports To: Plant Head
- Direct Reports: Shift Supervisors (4)
- Indirect Reports: Helpers

(J) Remuneration

- Competitive compensation package commensurate with experience and industry standards.
- Benefits as per company policy.

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