Maintenance Manager

Role Overview:
As Maintenance Manager for our Hosur facility, you will own equipment availability, reliability and efficiency across every manufacturing line and plant utility. You will lead preventive, predictive and breakdown maintenance, drive TPM and reliability engineering, and push automation and continuous improvement — building the maintenance system that lets the plant scale with a business growing ~28% a year.
Key Responsibilities:
1. Equipment Reliability & Plant Availability
Ensure maximum machine uptime across all manufacturing lines.
Drive preventive, predictive, and condition-based maintenance programs.
Minimize unplanned equipment breakdowns through structured reliability initiatives.
Improve Overall Equipment Effectiveness (OEE) by reducing maintenance-related losses.
Develop and monitor MTBF, MTTR, Technical Availability, and Equipment Reliability metrics.
2. Total Productive Maintenance (TPM)
Lead TPM implementation across all manufacturing departments.
Establish Autonomous Maintenance and Planned Maintenance pillars.
Develop machine-wise TPM checklists, standards, lubrication plans, and inspection schedules.
Continuously improve TPM points based on recurring failures and root cause analysis.
Drive operator ownership through Autonomous Maintenance practices and capability building.
Monitor TPM compliance through regular audits and sustainment reviews.
3. Preventive & Predictive Maintenance
Prepare Annual, Quarterly, Monthly, and Weekly Preventive Maintenance schedules.
Implement predictive maintenance techniques including vibration analysis, thermography, condition monitoring, and failure trend analysis wherever applicable.
Ensure timely execution of planned maintenance activities with minimal production disruption.
Standardize maintenance procedures and preventive maintenance checklists.
4. Breakdown Management & Root Cause Analysis
Ensure rapid response to equipment breakdowns.
Lead structured Root Cause Analysis (5 Why, Fishbone, PDCA, CAPA).
Eliminate repetitive failures through permanent corrective actions.
Maintain detailed breakdown history and trend analysis for continuous improvement.
5. Utilities & Infrastructure Maintenance
Ensure reliable operation of plant utilities including compressors, DG sets, electrical systems, HVAC, dust extraction systems, air lines, and other infrastructure.
Monitor utility consumption and identify opportunities for energy optimization and cost reduction.
Ensure statutory compliance for all utility equipment.
6. Spare Parts & Asset Management
Develop critical spare inventory strategies.
Optimize maintenance inventory while avoiding stock-outs.
Lead localization of spare parts and vendor development initiatives.
Control maintenance budgets and improve spare utilization.
Maintain complete asset history and maintenance documentation through CMMS/ERP systems.
7. Continuous Improvement
Lead Kaizen, Cost Reduction, Productivity Improvement, and Reliability Enhancement projects.
Identify opportunities to reduce maintenance costs without compromising equipment reliability.
Drive automation, machine modifications, and engineering improvements.
Support new equipment installation, commissioning, and process stabilization.
8. Safety, Compliance & Sustainability
Ensure safe maintenance practices through Permit-to-Work systems, LOTO, and statutory compliance.
Maintain compliance with electrical, mechanical, environmental, and safety regulations.
Conduct safety audits and eliminate unsafe conditions.
Promote a Zero Accident culture within the maintenance team.
9. Team Leadership
Lead and mentor maintenance engineers, supervisors, technicians, and contract manpower.
Develop competency matrices and structured technical training programs.
Plan manpower deployment and shift schedules to ensure effective maintenance coverage.
Foster a culture of ownership, accountability, and continuous learning.
10. Cross-Functional Collaboration
Partner with Production, Quality, Industrial Engineering, Projects, SCM, and EHS teams to improve plant performance.
Support new product introductions, capacity expansion, and process improvement initiatives.
Participate in daily production reviews and operational excellence meetings.
Key Performance Indicators (KPIs)
Machine Uptime (%)
Overall Equipment Effectiveness (OEE)
Mean Time Between Failures (MTBF)
Mean Time to Repair (MTTR)
Planned Maintenance Compliance (%)
Breakdown Frequency
TPM Audit Score
Equipment Technical Availability
Maintenance Cost vs Budget
Spare Parts Inventory Accuracy
Energy Consumption Reduction
Safety Compliance & Zero Lost-Time Incidents
Kaizen & Cost Saving Projects Delivered
Essential Qualifications
Bachelor's Degree in Mechanical, Electrical, Electronics, Mechatronics, Instrumentation, or Industrial Engineering.
10 to 15 years of maintenance experience in manufacturing.
Minimum 4 years of experience leading maintenance teams.
Strong expertise in preventive, predictive, and breakdown maintenance.
Hands-on experience with TPM deployment, OEE improvement, and reliability engineering.
Knowledge of PLCs, automation systems, electrical and mechanical maintenance, pneumatics, hydraulics, utilities, and industrial equipment.
Experience with CMMS/ERP-based maintenance management.
Good to have:
TPM, Lean Manufacturing or Reliability Engineering certification; Six Sigma Green Belt / Black Belt.
Experience in Furniture, Wood Products, Consumer Durables, Automotive or Heavy Engineering industries.
Exposure to automation, robotics and Industry 4.0 maintenance practices.

Work arrangement
No