Role & responsibilities

A. Pan-India Maintenance Strategy and Governance

- Develop and implement a standardised maintenance strategy for all repacking centres.
- Establish common maintenance processes, preventive maintenance schedules, inspection standards and equipment-wise maintenance protocols.
- Define maintenance organisation structures, manpower requirements, roles and responsibilities for each centre.
- Establish standard operating procedures, maintenance checklists, escalation mechanisms and performance review systems.
- Conduct periodic reviews of maintenance performance across centres and drive closure of identified gaps.
- Develop a maintenance capability roadmap aligned with business growth, new centre commissioning and capacity expansion.

B. Equipment Reliability and Downtime Reduction

- Drive improvement in equipment availability and reliability across all repacking centres.
- Establish standardised measurement and reporting of equipment-wise downtime, breakdown frequency, MTBF and MTTR.
- Review major and repetitive breakdowns and ensure structured root-cause analysis and permanent corrective actions.
- Identify chronic equipment failures and implement network-wide solutions to prevent recurrence.
- Benchmark equipment performance across centres and replicate successful reliability practices.
- Work with Operations to minimise production losses attributable to equipment breakdowns, speed losses and frequent stoppages.

C. Preventive and Predictive Maintenance Excellence

- Ensure implementation and adherence to preventive maintenance schedules across all centres.
- Establish systems to monitor maintenance compliance, overdue activities and repeat failures.
- Introduce condition-based and predictive maintenance practices wherever technically and commercially viable.
- Standardise lubrication practices, inspection routines, equipment servicing and maintenance history documentation.
- Drive equipment health assessments and prioritise maintenance interventions based on criticality and operational risk.
- Ensure planned maintenance is integrated with production schedules to minimise disruption to operations.

D. Spare-Parts Strategy and Inventory Optimisation

- Establish a Pan-India critical spare-parts framework based on equipment criticality, failure history, consumption and supplier lead times.
- Standardise spare-parts specifications across centres wherever technically feasible.
- Define inventory norms, minimum and maximum stock levels, replenishment mechanisms and emergency procurement protocols.
- Ensure availability of critical spares to prevent prolonged production downtime.
- Monitor spare-parts consumption, inventory ageing, stock-outs, obsolete inventory and emergency purchases.
- Work with Procurement, Stores and OEMs to improve sourcing efficiency, negotiate service arrangements and optimise spare-parts costs.
- Evaluate opportunities for common inventories, inter-centre transfers and centralised procurement.

E. Productivity, OEE and Process Efficiency

- Drive improvement in Overall Equipment Effectiveness (OEE), machinery throughput and equipment performance in partnership with Operations.
- Identify equipment-related constraints affecting repacking speed, line efficiency, output and capacity utilisation.




- Lead technical interventions to reduce minor stoppages, speed losses, changeover losses and recurring equipment-related wastage.
- Support equipment capability assessments and identify opportunities to improve machine utilisation and throughput.
- Evaluate and recommend equipment modifications, upgrades and reliability improvements based on operational perks and payback.
- Track the impact of maintenance initiatives on productivity, output per shift and cost per tonne.

F. Kaizen, TPM and TQM

- Lead maintenance-related continuous improvement initiatives across all repacking centres.
- Establish structured Kaizen programmes focused on breakdown elimination, equipment reliability, productivity and cost reduction.
- Drive Total Productive Maintenance (TPM), 5S and relevant TQM practices in collaboration with Operations and Quality.
- Implement structured problem-solving methodologies, including 5 Why analysis, fishbone analysis and corrective/preventive action tracking.
- Promote operator-led basic equipment care, including cleaning, inspection and early identification of abnormalities.
- Identify and replicate best practices across centres and build a repository of proven technical improvements.
- Measure and report the financial and operational benefits delivered through maintenance-led improvements. Closely work with the COE to improve the efficacy.

G. Maintenance Cost and Budget Management

- Prepare and manage the annual maintenance budget across all repacking centres.
- Establish benchmarks for maintenance cost per tonne, cost per machine or line, spare-parts consumption and external servicing expenditure, as appropriate.
- Monitor centre-wise and network-wide maintenance expenditure against approved budgets.
- Drive optimisation of repair costs, spare consumption, service contracts and maintenance manpower productivity.
- Evaluate repair-versus-replacement decisions for ageing or unreliable equipment.
- Build business cases for major maintenance interventions, equipment upgrades and reliability investments.
- Ensure cost reduction initiatives do not compromise equipment reliability, food safety or workplace safety.

H. Technical Projects and New Centre Commissioning

- Provide maintenance inputs during the planning and selection of new repacking machinery and equipment.
- Coordinate with the Projects team during new centre development, expansion and capacity-enhancement projects.
- Define maintenance-readiness requirements for new equipment, including documentation, critical spares, servicing arrangements and maintenance access.
- Participate in equipment installation, commissioning, performance validation and operational handover.
- Ensure maintenance teams are trained before new machinery is handed over for regular production.
- Review equipment performance after commissioning and ensure closure of reliability and maintainability issues.




- Coordinate with central MEP and Civil teams on interfaces affecting machinery installation and maintenance, while keeping ownership of MEP and civil maintenance separate.

I. Team Leadership and Capability Development

- Lead, coach and develop unit-level maintenance managers and their teams across India.
- Establish competency requirements and structured technical training programmes for maintenance personnel.
- Develop standard skill matrices, training plans and assessments for critical equipment and maintenance practices.
- Build technical troubleshooting capabilities to reduce dependency on OEMs and external service providers where feasible.
- Review centre-wise manpower adequacy, shift coverage and technical capability.
- Establish performance goals and periodic reviews for maintenance managers based on reliability, downtime, preventive maintenance and cost outcomes.
- Promote a culture of accountability, root-cause resolution, safety and continuous improvement.

J. Safety, Food Safety and Compliance

- Ensure maintenance activities comply with applicable machinery safety requirements, isolation and lockout/tagout procedures.
- Ensure machine guards, interlocks and safety devices remain functional and are not bypassed.
- Drive compliance with food-safety and hygiene requirements during maintenance interventions in repacking areas.
- Establish standards for tool control, lubrication, maintenance materials and prevention of foreign-body contamination.
- Ensure timely closure of maintenance-related audit findings, safety observations and recurring non-conformities.
- Coordinate with Quality, Safety and the relevant MEP/Civil teams on cross-functional compliance requirements.

K. Maintenance MIS and Performance Reviews

- Develop a common Pan-India maintenance dashboard with centre-wise and consolidated performance indicators.
- Establish daily or shift-level breakdown reporting at unit level and periodic performance reviews at regional and national levels.
- Conduct monthly maintenance performance reviews with unit maintenance managers and relevant Operations leaders.
- Benchmark centre performance and identify underperforming equipment, recurring failures and opportunities for intervention.
- Track action plans, accountability and completion timelines for major maintenance improvement initiatives.
- Present periodic performance updates, risks and investment requirements to business leadership.

Preferred candidate profile

- Experience leading maintenance across multiple factories, plants, warehouses with production operations or packaging facilities.
- Experience in industrial maintenance, manufacturing, food processing, FMCG or packaging operations, with demonstrated multi-site responsibility.
- Strong knowledge of preventive and predictive maintenance, equipment reliability, breakdown analysis, critical spare-parts management and maintenance planning.
- Practical experience with OEE, MTBF, MTTR, TPM, TQM, Kaizen and structured problem-solving.
- Experience managing maintenance budgets, technical teams, OEMs, vendors and equipment-related capital projects.
- Strong analytical capability, leadership skills, stakeholder management and willingness to travel across India.

Keen candidates can apply your resume on [email protected]/(phone hidden)

📌 Maintenance Manager (Mumbai)
🏢 Dmart
📍 Mumbai