Senior Manager - Eei, Nagpur Plant Job in Ceat Ltd

Key Purpose of the Job (Position Summary)

This position is responsible to ensure effective up keep and maintenance of all electrical and instrumentation equipment at the plant to ensure maximum equipment availability and minimum downtime on account of breakdown. The role incumbent shall lead a team of Electrical and Instrumentation engineers to ensure all maintenance jobs are completed as per schedule and within the defined budget.

KEY PERFORMANCE AREAS

• Adherence to maintenance schedule and budget
• OEE Improvement (Uniformity)
• Plant Reliability Index
• Reduction in repetitive breakdown occurrences (Hours and Instances)
• Reduction in cost of maintenance (Stores, spares and repair maintenance cost)
• Reduction in energy cost (Power ratio)
• Plant safety and environment
• Improvement initiatives (SPARSH Machine, Kaizen, HIRA etc.)
• Compliance as per statutory standards for electrical installations and weights & measures

KEY ACTIVITIES & RESPONSIBILITIES

Planning & Budgeting

• Plan the annual maintenance schedule and activities for all electronics and instrumentation section in consultation with Plant Chief Engineer
• Participate in preparation of the annual maintenance budget by providing inputs for the electronics and instrumentation section
• Provide inputs for the procurement plan for electronics and instrumentation sections covering requirement for consumables, spare parts, maintenance supplies and tools
• Support the IT team in identifying vendors and suppliers for management of the Electronics systems run by SCADA
• Liaise with suppliers and vendors to develop a long term maintenance plan for the machinery (On AMCs)
• Identify and carryout standardization and reliability improvement initiatives
• Develop SOP for electronic networks and systems with a focus on maintaining increased uptime

Maintenance Operations

Planned Maintenance

• Work with the team to schedule and prioritize work orders to ensure optimum utilization of resources and minimum disturbance to production activities
• Manage and supervise all the maintenance activities undertaken by the electronics and instrumentation team to ensure the same is as per the maintenance schedule and budget and is of high quality
• Work closely with other departments to ensure maintenance schedules are adhered to without disruption of production targets
• Prepare schedule for maintenance activities during shutdown and ensure proper execution of the same as per shutdown schedule
• Ensure that all electronics equipments are regularly calibrated as per schedule by the team and in an efficient manner with minimal issues
• For equipment covered under AMCs, ensure regular maintenance is done by the vendor in accordance to the terms and conditions agreed in the AMC

Breakdown Maintenance

• Prioritize breakdown repair jobs as per criticality to the production process
• Ensure the team provides timely and effective break down maintenance support for any of the electronics and instrumentation systems or network issues at the plant
• Review any major breakdowns in electronics and instrumentation systems or networks to assess the scope of repair work required, cost for the repairs and other resources required
• Oversee any major breakdown repair work to validate the quality of the work done and ensure minimum repetition of similar incidents
• Ensure that the team prepares SOPs for any break down repairs and maintenance for reference in future occurrences
• Provide technical guidance to the team for complex repairs and issues

Procurement

• Regularly monitor availability of spares and work with the team to ensure optimum inventory of spares for the section
• For any new spares or material prepare technical specification and provide same to procurement team post approval from Chief Engineer
• Work with the procurement team in evaluating vendors and shortlisting as required
• Review and validate technical terms and conditions of agreements with vendors

Others

• Ensure the team adheres to the companys maintenance standards, norms and laid down policies
• Where required liaison with the statutory bodies and government authorities for any statutory compliances related to the electrical and instrumentation section in the plant
• Resolve any coordination issues the team may face with other departments to ensure maintenance work does not get hampered
• Drive improvement initiatives such as QIPs, Kaizen, Muri Mura etc. for the team

Cost Management

• Monitor maintenance expenditure to ensure compliance to the budget
• Monitor consumption of all consumables and spares
• Monitor and report power consumption at the plant, department wise and suggest measures for power saving
• Ensure all maintenance jobs done by the team are undertaken with optimum use of resources and minimum wastage
• Identify areas for cost saving in the electronics and instrumentation section and recommend action plan to achieve the saving

Projects (as applicable)

• Ensure all maintenance related jobs for any major plant wide improvement projects / capex projects are completed in time such as new machine installation, replacement, etc.
• Support the projects team in streamlining the production process while expanding plant operations and ensure that all electronics network and systems are performing as per the desired results
• Be up-to-date on new technology, understand position relative to competition and recommend changes for enhanced performance

MIS & Reporting

• Ensure records of all service, maintenance and refurbishing works carried out in electronics and instrumentation section are maintained
• Ensure records of all electrical equipment history maintained
• Review SAP regularly to ensure accuracy of data and information regarding maintenance

Health & Safety

• Ensure all maintenance activities in the section are carried out in complete adherence of the safety, health and environmental policies and procedures for the Plant.
• Ensure safety measures are consistently followed and take initiative to enhance acceptance of safety as a culture so as to achieve zero accident level
• Train employees on various electrical equipment, networks and SCADA management to ensure sensitization to the correct methods of handling the same

• Report any incident to the Chief Engineer immediately

People and Relationship Management

• Guide and manage the team to ensure the departments objectives are met
• Ensure that team is adequately trained and proactively work with HR at capability enhancement of team
• Conduct effective performance appraisals for the team and provide regular feedback
• Motivate, counsel and coach employees to ensure a conducive working environment
• Work effectively with network / SCADA vendors and vendor teams for enhanced performance
• Drive development of electronics systems and networks with support of our vendors

Education and Experience Required

Education:

B.E.- Electrical/ Electronics and Instrumentation/ Electrical and Electronics

Experience:

12 + years of experience in a shop floor maintenance with about 4-5 years experience of leading a maintenance team preferable in a modern automated environment that is supported by SCADA systems