Assistant Manager - Mechanical Maintenance

Description
Job Purpose

To ensure the reliable and efficient operation of plant machinery, production equipment, utilities, and electrical/mechanical systems through effective preventive, predictive, and breakdown maintenance. The role will support plant uptime, equipment reliability, safety, and continuous improvement across the BESS/battery manufacturing facility.

Key Responsibilities 1. Preventive & Predictive Maintenance

• Develop and execute preventive maintenance schedules for plant machinery and equipment.


• Ensure timely completion of scheduled maintenance activities.


• Monitor equipment health and identify potential failures through predictive maintenance techniques.


• Maintain equipment history, maintenance records, checklists, and inspection reports.


• Analyse recurring equipment failures and implement corrective actions.

2. Breakdown Maintenance

• Lead troubleshooting and resolution of mechanical and electrical equipment breakdowns.


• Minimize equipment downtime and restore production operations within defined timelines.


• Conduct Root Cause Analysis (RCA) for major and repetitive breakdowns.


• Coordinate with production teams to prioritize critical equipment maintenance.


• Maintain breakdown reports and downtime analysis.

3. Battery Manufacturing Equipment Maintenance

Support maintenance of equipment associated with battery/cell/BESS manufacturing, such as:

• Mixing machines


• Coating machines


• Drying ovens


• Calendering machines


• Slitting machines


• Winding/stacking machines


• Welding equipment


• Electrolyte filling systems


• Formation and aging equipment


• Battery testing equipment


• Assembly and automation systems


• Conveyors and material-handling equipment


• HVAC and dry-room systems

4. Electrical Maintenance

• Maintain plant electrical systems including LT/HT panels, MCCs, PCCs, transformers, DG sets, UPS and distribution systems.


• Monitor motors, drives, VFDs, sensors, PLCs and control systems.


• Troubleshoot electrical faults and support automation teams in equipment-related issues.


• Ensure electrical systems operate safely and reliably.


• Coordinate statutory inspections and electrical safety requirements.

5. Mechanical Maintenance

• Ensure reliable operation of pumps, motors, compressors, gearboxes, conveyors, valves, piping and other mechanical systems.


• Monitor lubrication schedules and ensure appropriate lubrication practices.


• Support alignment, balancing and vibration monitoring activities.


• Maintain critical mechanical spares and components.

6. Utilities & Facility Maintenance

• Support maintenance of critical plant utilities such as:
  
  
  
  • HVAC
  
  
  • Chillers
  
  
  • Cooling towers
  
  
  • Compressed air systems
  
  
  • Pumps
  
  
  • Water-treatment systems
  
  
  • Fire-fighting systems
  
  
  • DG sets
  
  
  • ETP/STP
  
  


• Ensure uninterrupted availability of utilities required for production.

7. Automation & Controls

• Coordinate with automation teams for PLC, HMI, SCADA and sensor-related maintenance.


• Support troubleshooting of automated production equipment.


• Ensure proper functioning of safety interlocks, alarms and emergency-stop systems.


• Support equipment parameter monitoring and optimization.

8. Spare Parts & Inventory Management

• Identify and maintain an inventory of critical maintenance spares.


• Prepare spare-part requirements based on equipment criticality and consumption.


• Coordinate with Procurement for timely availability of critical spares.


• Monitor spare consumption and optimize maintenance inventory.


• Maintain equipment BOMs and spare-part records in ERP/CMMS.

9. Safety & Compliance

• Ensure maintenance activities are carried out in accordance with EHS procedures.


• Follow LOTO (Lockout/Tagout) procedures during maintenance activities.


• Ensure proper use of PPE and safe working practices.


• Participate in safety audits, risk assessments and incident investigations.


• Ensure compliance with statutory and plant safety requirements.

10. Vendor & Contractor Management

• Coordinate with external maintenance agencies, OEMs and service providers.


• Supervise contractor activities at the plant.


• Ensure vendors adhere to safety, quality and maintenance requirements.


• Coordinate equipment AMC/CMC activities and service visits.


• Evaluate vendor performance and escalate recurring issues.

11. Continuous Improvement

• Identify opportunities to improve equipment reliability, OEE and maintenance efficiency.


• Implement initiatives to reduce breakdown frequency and maintenance costs.


• Support TPM, Kaizen, Lean and reliability improvement initiatives.


• Monitor KPIs such as MTBF, MTTR, equipment availability and downtime.

12. Team Management

• Supervise maintenance engineers, technicians and contract manpower.


• Allocate daily maintenance activities and monitor execution.


• Conduct toolbox talks and technical training for maintenance personnel.


• Ensure adequate manpower coverage for shifts and critical operations.