This role involves developing and implementing a standardized maintenance strategy across all repacking centers in India. The Maintenance Manager will focus on improving equipment reliability, optimizing spare parts, and driving continuous improvement initiatives to enhance productivity and efficiency. This position suits a leader with strong analytical and stakeholder management skills, willing to travel across India.
Responsibilities
Develop and implement a standardized maintenance strategy for all repacking centers
Establish common maintenance processes, preventive maintenance schedules, inspection standards, and equipment-wise maintenance protocols
Define maintenance organization structures, manpower requirements, roles, and responsibilities for each center
Establish standard operating procedures, maintenance checklists, escalation mechanisms, and performance review systems
Conduct periodic reviews of maintenance performance across centers and drive closure of identified gaps
Develop a maintenance capability roadmap aligned with business growth, new center commissioning, and capacity expansion
Drive improvement in equipment availability and reliability across all repacking centers
Establish standardized measurement and reporting of equipment-wise downtime, breakdown frequency, MTBF, and MTTR
Review major and repetitive breakdowns and ensure structured root-cause analysis and permanent corrective actions
Identify chronic equipment failures and implement network-wide solutions to prevent recurrence
Benchmark equipment performance across centers and replicate successful reliability practices
Work with Operations to minimize production losses attributable to equipment breakdowns, speed losses, and frequent stoppages
Ensure implementation and adherence to preventive maintenance schedules across all centers
Establish systems to monitor maintenance compliance, overdue activities, and repeat failures
Introduce condition-based and predictive maintenance practices wherever technically and commercially viable
Standardize lubrication practices, inspection routines, equipment servicing, and maintenance history documentation
Drive equipment health assessments and prioritize maintenance interventions based on criticality and operational risk
Ensure planned maintenance is integrated with production schedules to minimize disruption to operations
Establish a Pan-India critical spare-parts framework based on equipment criticality, failure history, consumption, and supplier lead times
Standardize spare-parts specifications across centers wherever technically feasible
Define inventory norms, minimum and maximum stock levels, replenishment mechanisms, and emergency procurement protocols
Millions of jobs, with real people getting hired every day
200,000+
New jobs added daily
7,000,000+
Verified job listings
1,000,000+
Tailored applications submitted
Ensure availability of critical spares to prevent prolonged production downtime
Work with Procurement, Stores, and OEMs to improve sourcing efficiency, negotiate service arrangements, and optimize spare-parts costs
Evaluate opportunities for common inventories, inter-center transfers, and centralized procurement
Drive improvement in Overall Equipment Effectiveness (OEE), machinery throughput, and equipment performance in partnership with Operations
Identify equipment-related constraints affecting repacking speed, line efficiency, output, and capacity utilization
Lead technical interventions to reduce minor stoppages, speed losses, changeover losses, and recurring equipment-related wastage
Support equipment capability assessments and identify opportunities to improve machine utilization and throughput
Evaluate and recommend equipment modifications, upgrades, and reliability improvements based on operational benefits and payback
Track the impact of maintenance initiatives on productivity, output per shift, and cost per tonne
Lead maintenance-related continuous improvement initiatives across all repacking centers
Establish structured Kaizen programs focused on breakdown elimination, equipment reliability, productivity, and cost reduction
Drive Total Productive Maintenance (TPM), 5S, and relevant TQM practices in collaboration with Operations and Quality
Implement structured problem-solving methodologies, including 5 Why analysis, fishbone analysis, and corrective/preventive action tracking
Promote operator-led basic equipment care, including cleaning, inspection, and early identification of abnormalities
Identify and replicate best practices across centers and build a repository of proven technical improvements
Measure and report the financial and operational benefits delivered through maintenance-led improvements
Closely work with the COE to improve the efficacy
Prepare and manage the annual maintenance budget across all repacking centers
Establish benchmarks for maintenance cost per tonne, cost per machine or line, spare-parts consumption, and external servicing expenditure, as appropriate
Monitor center-wise and network-wide maintenance expenditure against approved budgets
Drive optimization of repair costs, spare consumption, service contracts, and maintenance manpower productivity
Evaluate repair-versus-replacement decisions for aging or unreliable equipment
Build business cases for major maintenance interventions, equipment upgrades, and reliability investments
Ensure cost reduction initiatives do not compromise equipment reliability, food safety, or workplace safety
Provide maintenance inputs during the planning and selection of new repacking machinery and equipment
Coordinate with the Projects team during new center development, expansion, and capacity-enhancement projects
Define maintenance-readiness requirements for new equipment, including documentation, critical spares, servicing arrangements, and maintenance access
Participate in equipment installation, commissioning, performance validation, and operational handover
Ensure maintenance teams are trained before new machinery is handed over for regular production
Review equipment performance after commissioning and ensure closure of reliability and maintainability issues
Coordinate with central MEP and Civil teams on interfaces affecting machinery installation and maintenance, while keeping ownership of MEP and civil maintenance separate
Lead, coach, and develop unit-level maintenance managers and their teams across India
Establish competency requirements and structured technical training programs for maintenance personnel
Develop standard skill matrices, training plans, and assessments for critical equipment and maintenance practices
Build technical troubleshooting capabilities to reduce dependency on OEMs and external service providers where feasible
Review center-wise manpower adequacy, shift coverage, and technical capability
Establish performance goals and periodic reviews for maintenance managers based on reliability, downtime, preventive maintenance, and cost outcomes
Promote a culture of accountability, root-cause resolution, safety, and continuous improvement
Ensure maintenance activities comply with applicable machinery safety requirements, isolation, and lockout/tagout procedures
Ensure machine guards, interlocks, and safety devices remain functional and are not bypassed
Drive compliance with food-safety and hygiene requirements during maintenance interventions in repacking areas
Establish standards for tool control, lubrication, maintenance materials, and prevention of foreign-body contamination
Ensure timely closure of maintenance-related audit findings, safety observations, and recurring non-conformities
Coordinate with Quality, Safety, and the relevant MEP/Civil teams on cross-functional compliance requirements
Develop a common Pan-India maintenance dashboard with center-wise and consolidated performance indicators
Establish daily or shift-level breakdown reporting at unit level and periodic performance reviews at regional and national levels
Conduct monthly maintenance performance reviews with unit maintenance managers and relevant Operations leaders
Benchmark center performance and identify underperforming equipment, recurring failures, and opportunities for intervention
Track action plans, accountability, and completion timelines for major maintenance improvement initiatives
Present periodic performance updates, risks, and investment requirements to business leadership
Requirements
Experience leading maintenance across multiple factories, plants, warehouses with production operations or packaging facilities
Experience in industrial maintenance, manufacturing, food processing, FMCG, or packaging operations, with demonstrated multi-site responsibility
Strong knowledge of preventive and predictive maintenance, equipment reliability, breakdown analysis, critical spare-parts management, and maintenance planning
Practical experience with OEE, MTBF, MTTR, TPM, TQM, Kaizen, and structured problem-solving
Experience managing maintenance budgets, technical teams, OEMs, vendors, and equipment-related capital projects
Strong analytical capability, leadership skills, stakeholder management, and willingness to travel across India
