1. Maintenance Planning & Execution

• Develop and implement preventive maintenance (PM) schedules for injection molding machines, extruders, blow molding machines, chillers, compressors, granulators, dryers, and auxiliary equipment.
• Plan and supervise predictive maintenance programs (vibration analysis, thermography, oil analysis) to reduce unplanned breakdowns.
• Coordinate corrective and breakdown maintenance to minimize production downtime.

2. Team Management

• Lead, train, and supervise the maintenance team (electricians, mechanics, technicians, and maintenance supervisors).
• Allocate manpower and resources efficiently across shifts.
• Conduct performance evaluations and identify training needs for skill development.

3. Equipment & Spare Parts Management

• Maintain optimum inventory of critical spare parts, tools, and consumables.
• Manage vendor relationships for equipment servicing, calibration, and procurement of spares.
• Maintain equipment history records, breakdown logs, and maintenance reports.

4. Mold & Tooling Maintenance

• Oversee maintenance and repair of molds, dies, and tooling used in plastic processing.
• Coordinate with the toolroom for mold modifications, repairs, and trial runs.

5. Utilities & Facility Management

• Ensure smooth operation of utilities such as chillers, cooling towers, air compressors, DG sets, water treatment plants, and electrical systems.
• Plan energy conservation initiatives and monitor utility consumption.

6. Quality, Safety & Compliance

• Ensure all maintenance activities comply with safety standards, ISO requirements, and statutory regulations.
• Implement and monitor Lockout-Tagout (LOTO) procedures and other safety protocols.
• Conduct root cause analysis (RCA) for recurring breakdowns and implement corrective actions (CAPA).

7. Budgeting & Cost Control

• Prepare and manage the maintenance budget, including manpower, spares, and contracted services.
• Identify cost-saving opportunities through process improvement and equipment optimization.

8. Continuous Improvement

• Drive TPM (Total Productive Maintenance) and 5S initiatives across the plant.
• Work closely with production, quality, and engineering teams to improve Overall Equipment Effectiveness (OEE).
• Evaluate and recommend new technologies or equipment upgrades.

9. Documentation & Reporting

• Maintain accurate maintenance records, checklists, and SOPs.
• Prepare daily, weekly, and monthly maintenance performance reports for management review.

• Bachelor's degree or Diploma in Mechanical, Electrical, or Industrial Engineering (or related field).
• Minimum 8-12 years of experience in maintenance, with at least 3-5 years in a managerial role within plastic manufacturing (injection molding, extrusion, blow molding, or related processes).
• Strong knowledge of plastic processing machinery (injection molding machines, extruders, blow molding machines, Cooling).
• Hands-on experience with hydraulics, pneumatics, PLCs, servo systems, and electrical control panels.
• Familiarity with mold maintenance and tooling.
• Knowledge of preventive/predictive maintenance tools and CMMS (Computerized Maintenance Management System) software.
• Understanding of energy management and utility systems (chillers, compressors, cooling towers).
• Strong leadership and team management abilities.
• Excellent problem-solving and analytical skills.
• Good communication and coordination skills across departments.
• Ability to work under pressure and manage multiple priorities.