Senior Maintenance Engineer - Plant Maintenance (Heavy Engineering & Fabrication)

• Plan, organize, and supervise preventive, predictive, corrective, and breakdown maintenance activities to ensure uninterrupted production.

• Maximize machine availability while minimizing equipment downtime and maintenance costs.

• Prioritize maintenance activities based on production requirements and equipment criticality.

• Lead daily maintenance planning meetings and ensure timely execution of maintenance schedules.

• Conduct Root Cause Analysis (RCA) for recurring equipment failures and implement sustainable corrective and preventive actions.

Preventive & Predictive Maintenance:

• Develop, implement, and continuously improve Preventive Maintenance (PM) schedules for all critical manufacturing equipment.

• Monitor PM compliance and identify opportunities to improve equipment reliability.

• Establish equipment maintenance history and reliability improvement programs.

Equipment & Utilities Maintenance:

Lead maintenance activities for:

• Welding and cutting machines

• Hydraulic and pneumatic systems

• Gearboxes, motors, pumps, compressors, and blowers

• EOT cranes and material handling equipment

• Fabrication machinery and production equipment

• Industrial utilities and supporting infrastructure

• Electrical systems associated with plant machinery

Reliability & Continuous Improvement:

• Drive TPM, 5S, Kaizen, and Lean Maintenance initiatives across the plant.

• Improve equipment reliability through predictive maintenance and condition monitoring.

• Identify opportunities to reduce downtime, maintenance costs, and energy consumption.

• Recommend and implement equipment modifications to improve productivity and operational efficiency.

Planning & Coordination:

• Coordinate closely with Production, Quality, Purchase, Stores, Projects, and Engineering teams.

• Plan shutdown maintenance and annual maintenance activities.

• Ensure availability of critical spare parts, maintenance consumables, and specialized tools.

• Coordinate with external vendors for AMC, inspections, repairs, calibration, and servicing.

Projects & Plant Expansion:

• Support installation, commissioning, relocation, and modification of machinery and utilities.

• Participate in plant expansion, automation, and capacity enhancement projects.

• Provide technical support during equipment procurement and commissioning.

Cost & Budget Management:

• Prepare and manage annual maintenance budgets.

• Monitor maintenance expenditure and optimize maintenance costs without compromising reliability.

• Manage CAPEX proposals related to equipment upgrades and new machinery.

Documentation & Compliance:

• Maintain maintenance records, equipment history, SOPs, PM checklists, drawings, manuals, and calibration records.

• Ensure compliance with statutory regulations, company standards, LOTO procedures, and safety requirements.

• Drive timely closure of internal and external audit observations.

• Machine Availability ≥ 95%

• Reduction in equipment breakdown hours

• Improvement in Mean Time Between Failures (MTBF)

• Reduction in Mean Time To Repair (MTTR)

• Preventive Maintenance Compliance

• Maintenance Cost Optimization

• Critical Spare Parts Availability

• Reduction in Repeat Equipment Failures

• Energy Efficiency Improvement

• Safety Compliance and Zero Lost Time Incidents

The ideal candidate should possess strong hands-on knowledge of:

• Preventive, predictive, and breakdown maintenance

• Mechanical and electrical maintenance practices

• Hydraulic and pneumatic systems

• Welding and cutting machinery

• Gearboxes, motors, pumps, compressors, and rotating equipment

• EOT cranes and material handling systems

• Fabrication machinery maintenance

• Maintenance planning and scheduling

• Spare parts planning and inventory management

• Root Cause Analysis (RCA)

• TPM, 5S, Kaizen, and Lean Manufacturing

• Machine installation and commissioning

• Equipment reliability and condition monitoring

• Heavy Engineering

• Pressure Vessel Manufacturing

• Process Equipment Manufacturing

• Oil & Gas Equipment

• Boiler Manufacturing

• Industrial Burners & Combustion Systems

• Steel & Metal Fabrication

• EPC Manufacturing

• Process Plants

• Industrial Machinery Manufacturing