Engineering Executive

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Job Title
Mechanical Maintenance & Projects Executive – Process Plant
Location
Hindustan Unilever Ltd., Hosur Beverages Factory
Purpose of the Role
To lead mechanical maintenance, reliability improvement and capital project execution across the coffee manufacturing process plant, ensuring safe, hygienic, reliable and cost-effective operations. The role is responsible for sustaining equipment availability, driving continuous improvement, executing engineering projects, and ensuring compliance with food safety, quality and hygiene standards.
Key Responsibilities
Mechanical Maintenance & Reliability
Own maintenance strategy and execution for critical process equipment including Roaster, Extractors, Evaporator, ATFE, Spray Dryer, Pumps, Conveyors, Cooling Towers, Chillers, DHUs, Compressors and associated utilities.
Drive preventive, predictive and condition-based maintenance programs to improve equipment reliability and reduce breakdown losses.
Monitor and improve key reliability metrics including MTBF, MTTR, OEE and breakdown losses.
Lead root cause analysis (RCA) of major equipment failures and implement sustainable corrective actions.
Manage mechanical shutdown planning and execution to achieve OTIF maintenance delivery.
Ensure compliance with statutory inspections and safety requirements.
Drive spare parts optimization, inventory control and maintenance cost reduction initiatives.
Support energy efficiency and sustainability projects across process and utility systems.
Food Safety, Quality & Hygiene Engineering
Ensure all engineering activities comply with GMP, HACCP, hygiene design and food safety requirements.
Lead hygienic equipment design reviews and implementation of engineering controls to eliminate contamination risks.
Ensure maintenance practices support allergen control, foreign body prevention, pest control and sanitation standards.
Participate in quality audits and drive closure of engineering-related observations.
Drive hygiene-focused improvements in process areas, utilities and packaging operations.
Engineering Projects
Prepare, evaluate and execute capital projects from concept to commissioning.
Develop technical specifications, RFQs, cost estimates and project schedules.
Manage contractors, vendors and consultants during project execution.
Ensure projects are delivered safely, within budget and on schedule.
Lead installation, commissioning and performance validation of new equipment and plant modifications.
Support factory digitalization, automation and process optimization initiatives.
Cost & Continuous Improvement
Deliver savings through reliability improvement, energy reduction and asset optimization.
Drive Unispark, productivity and factory cost reduction projects.
Support business cases, capex proposals and investment justification activities.
Identify opportunities to improve yield, uptime and operational efficiency.
Safety Leadership
Ensure strict compliance with SHE standards, PTW systems, LOTO requirements and contractor safety management.
Conduct risk assessments and implement engineering controls to eliminate hazards.
Lead investigation and closure of maintenance and project-related incidents and near misses.
Key Performance Indicators (KPIs)
Process Plant Equipment Availability (%)
Breakdown Losses / Unplanned Downtime
Maintenance Cost vs Budget
Preventive Maintenance Compliance (%)
Safety Performance (TRFR, Near Miss Closure, Audit Compliance)
Capital Project OTIF Delivery
Energy & Utility Savings
GMP / Quality Audit Compliance
Productivity & Unispark Savings Delivery
Education
B.E./B.Tech in Mechanical Engineering
Experience
Essential
5-10 years of experience in mechanical maintenance and project execution in a continuous process manufacturing environment.
Strong knowledge of rotating equipment, pumps, compressors, heat exchangers, evaporators, dryers and utility systems.
Experience in preventive, predictive and reliability-centered maintenance.
Preferred
Experience in Coffee, Food, Beverage, Dairy, Nutrition, FMCG or other hygienic process industries.
Prior experience in spray drying, extraction, evaporation, roasting or thermal process operations.
Exposure to GMP, HACCP and hygienic engineering principles.
Experience in SAP PM, Power BI or digital maintenance systems.
Knowledge of automation and process control systems will be an added advantage.
Critical Competencies
Mechanical troubleshooting
Project management
Reliability engineering
Root Cause Analysis
Contractor management
Food safety & hygienic design
Cost management
Stakeholder management
Continuous improvement mindset
Strong ownership and execution capability