Maintenance Head / Manager

Maintenance Manager

Who Knowledge about the machines. Like;- Robotic Arm / CNC / VMC / HMC / Gear Hobbing / Induction hardening / Conduction hardening/ Tempering furnace / Manual & Auto Grinding m/c Auto straightening / Broach Machine / Thread Rolling Etc. Scada System, Electrical / Mechanical Maintenance.

KPIs for a Maintenance Head:

1. Equipment Uptime
2. Maintenance team Management
3. Mean Time Between Failures (MTBF)
4. Mean Time to Repair (MTTR)
5. Maintenance Cost per Unit of Production
6. Planned Maintenance Percentage
7. Preventive Maintenance Compliance
8. Downtime
9. Work Order Backlog
10. Energy Efficiency
11. Work Order Completion Time
12. Staff Training and Development
13. IATF-16949 Compliances (TPM)

Key responsibilities:
1. Maintenance Planning and Strategy

• Develop and implement a comprehensive maintenance strategy to ensure the uninterrupted operation of production equipment. Plan, schedule, and oversee preventive, predictive, and corrective maintenance tasks for all machinery, including presses, injection molding machines, CNC machines, and assembly lines. Ensure that maintenance activities align with production schedules to avoid delays.

2. Team Leadership and Management

• Lead, manage, and train a team of maintenance technicians and engineers.
• Delegate maintenance tasks and ensure the team is adequately equipped and trained to carry out the work. Conduct regular performance reviews and provide guidance to improve team efficiency and productivity.

3. Equipment Maintenance and Optimization

• Oversee routine inspections, troubleshooting, and repair of production machinery.
• Ensure equipment reliability by identifying opportunities for improvement and implementing upgrades or replacements as needed. Monitor the performance of critical production equipment and take preventive actions to avoid breakdowns.

4. Inventory and Spare Parts Management

• Maintain an inventory of essential spare parts and tools required for the efficient operation of the machinery. Ensure the availability of high-demand parts and materials to prevent downtime. Manage relationships with suppliers to source parts in a cost-effective and timely manner.

5. Cost Control and Budgeting

• Develop and manage the maintenance department’s budget, ensuring cost-effective use of resources. Monitor and report on maintenance expenditures, identifying areas for cost savings without compromising safety or quality. Implement energy-saving initiatives to reduce utility costs and improve equipment energy efficiency.

6. Safety and Compliance

• Ensure all maintenance activities comply with safety regulations, environmental standards, and company policies. Conduct regular safety audits and training to ensure a safe working environment for all employees. Oversee the proper use of personal protective equipment (PPE) and ensure adherence to lock-out/tag-out procedures.

7. Root Cause Analysis and Problem Solving

• Lead root cause analysis for recurring equipment failures or production delays.
• Develop and implement corrective actions to resolve underlying issues and improve long-term reliability. Use data from equipment monitoring systems to identify potential issues before they result in downtime.

8. Continuous Improvement and Efficiency

• Implement continuous improvement programs such as Lean, TPM (Total Productive Maintenance), or Six Sigma to enhance equipment reliability and maintenance processes.
• Work closely with production, quality control, and engineering teams to improve machinery performance and reduce defects in manufactured parts.
• Track and report key performance indicators (KPIs) such as downtime, MTTR, MTBF, and maintenance costs.

9. Vendor and External Contractor Management

• Coordinate and manage external contractors for specialized maintenance tasks or equipment servicing. Ensure that contracts with external service providers are cost-effective and meet quality and safety standards.

10. Project Management

• Oversee or participate in new equipment installations, upgrades, or factory expansions.
• Manage equipment relocation, setup, or reconfiguration to optimize plant layout and production flow. Ensure that capital projects are executed on time, within budget, and according to safety standards.

11. Reporting and Documentation

• Maintain accurate records of all maintenance activities, including work orders, downtime, repairs, and costs.
• Provide regular reports on maintenance activities, performance metrics, and equipment status to senior management.
• Track warranty claims and coordinate with manufacturers for equipment replacements or repairs.