Senior Maintenance Engineer - Plant Maintenance (Heavy Engineering & Fabrication)

About Zeeco:

Experience:

• 10 to 12 years of experience
• Diploma / B.E. in Mechanical Engineering
• Proven hands-on experience with fabrication plant machinery, including welding/cutting setups, hydraulics, pneumatics, and cranes. Skilled in both mechanical and electrical preventive maintenance.
• Plan, organize, and supervise preventive, predictive, corrective, and breakdown maintenance activities to ensure uninterrupted production.
• Maximize machine availability while minimizing equipment downtime and maintenance costs.
• Prioritize maintenance activities based on production requirements and equipment criticality.
• Lead daily maintenance planning meetings and ensure timely execution of maintenance schedules.
• Conduct Root Cause Analysis (RCA) for recurring equipment failures and implement sustainable corrective and preventive actions.
• Develop, implement, and continuously improve Preventive Maintenance (PM) schedules for all critical manufacturing equipment.
• Monitor PM compliance and identify opportunities to improve equipment reliability.
• Establish equipment maintenance history and reliability improvement programs.
• Welding and cutting machines
• Hydraulic and pneumatic systems
• Gearboxes, motors, pumps, compressors, and blowers
• EOT cranes and material handling equipment
• Fabrication machinery and production equipment
• Industrial utilities and supporting infrastructure
• Electrical systems associated with plant machinery
• Drive TPM, 5S, Kaizen, and Lean Maintenance initiatives across the plant.
• Improve equipment reliability through predictive maintenance and condition monitoring.
• Identify opportunities to reduce downtime, maintenance costs, and energy consumption.
• Recommend and implement equipment modifications to improve productivity and operational efficiency.
• Coordinate closely with Production, Quality, Purchase, Stores, Projects, and Engineering teams.
• Plan shutdown maintenance and annual maintenance activities.
• Ensure availability of critical spare parts, maintenance consumables, and specialized tools.
• Coordinate with external vendors for AMC, inspections, repairs, calibration, and servicing.
• Support installation, commissioning, relocation, and modification of machinery and utilities.
• Participate in plant expansion, automation, and capacity enhancement projects.
• Provide technical support during equipment procurement and commissioning.
• Prepare and manage annual maintenance budgets.
• Monitor maintenance expenditure and optimize maintenance costs without compromising reliability.
• Manage CAPEX proposals related to equipment upgrades and new machinery.
• Maintain maintenance records, equipment history, SOPs, PM checklists, drawings, manuals, and calibration records.
• Ensure compliance with statutory regulations, company standards, LOTO procedures, and safety requirements.
• Drive timely closure of internal and external audit observations.
• Machine Availability ≥ 95%
• Reduction in equipment breakdown hours
• Improvement in Mean Time Between Failures (MTBF)
• Reduction in Mean Time To Repair (MTTR)
• Preventive Maintenance Compliance
• Maintenance Cost Optimization
• Critical Spare Parts Availability
• Reduction in Repeat Equipment Failures
• Energy Efficiency Improvement
• Safety Compliance and Zero Lost Time Incidents
• Preventive, predictive, and breakdown maintenance
• Mechanical and electrical maintenance practices
• Welding and cutting machinery
• Gearboxes, motors, pumps, compressors, and rotating equipment
• EOT cranes and material handling systems
• Fabrication machinery maintenance
• Maintenance planning and scheduling
• Spare parts planning and inventory management
• Root Cause Analysis (RCA)
• TPM, 5S, Kaizen, and Lean Manufacturing
• Machine installation and commissioning
• Equipment reliability and condition monitoring
• Heavy Engineering
• Pressure Vessel Manufacturing
• Process Equipment Manufacturing
• Oil & Gas Equipment
• Boiler Manufacturing
• Industrial Burners & Combustion Systems
• Steel & Metal Fabrication
• EPC Manufacturing
• Process Plants
• Industrial Machinery Manufacturing

Qualification:

Key Responsibilities:

• Maintenance Operations:
• Plan, organize, and supervise preventive, predictive, corrective, and breakdown maintenance activities to ensure uninterrupted production.
• Maximize machine availability while minimizing equipment downtime and maintenance costs.
• Prioritize maintenance activities based on production requirements and equipment criticality.
• Lead daily maintenance planning meetings and ensure timely execution of maintenance schedules.
• Conduct Root Cause Analysis (RCA) for recurring equipment failures and implement sustainable corrective and preventive actions.
• Develop, implement, and continuously improve Preventive Maintenance (PM) schedules for all critical manufacturing equipment.
• Monitor PM compliance and identify opportunities to improve equipment reliability.
• Establish equipment maintenance history and reliability improvement programs.
• Lead maintenance activities for:
• Welding and cutting machines
• Hydraulic and pneumatic systems
• Gearboxes, motors, pumps, compressors, and blowers
• EOT cranes and material handling equipment
• Fabrication machinery and production equipment
• Industrial utilities and supporting infrastructure
• Electrical systems associated with plant machinery
• Drive TPM, 5S, Kaizen, and Lean Maintenance initiatives across the plant.
• Improve equipment reliability through predictive maintenance and condition monitoring.
• Identify opportunities to reduce downtime, maintenance costs, and energy consumption.
• Recommend and implement equipment modifications to improve productivity and operational efficiency.
• Coordinate closely with Production, Quality, Purchase, Stores, Projects, and Engineering teams.
• Plan shutdown maintenance and annual maintenance activities.
• Ensure availability of critical spare parts, maintenance consumables, and specialized tools.
• Coordinate with external vendors for AMC, inspections, repairs, calibration, and servicing.
• Support installation, commissioning, relocation, and modification of machinery and utilities.
• Participate in plant expansion, automation, and capacity enhancement projects.
• Provide technical support during equipment procurement and commissioning.
• Prepare and manage annual maintenance budgets.
• Monitor maintenance expenditure and optimize maintenance costs without compromising reliability.
• Manage CAPEX proposals related to equipment upgrades and new machinery.
• Maintain maintenance records, equipment history, SOPs, PM checklists, drawings, manuals, and calibration records.
• Ensure compliance with statutory regulations, company standards, LOTO procedures, and safety requirements.
• Drive timely closure of internal and external audit observations.
• Machine Availability ≥ 95%
• Reduction in equipment breakdown hours
• Improvement in Mean Time Between Failures (MTBF)
• Reduction in Mean Time To Repair (MTTR)
• Preventive Maintenance Compliance
• Maintenance Cost Optimization
• Critical Spare Parts Availability
• Reduction in Repeat Equipment Failures
• Energy Efficiency Improvement
• Safety Compliance and Zero Lost Time Incidents
• The ideal candidate should possess strong hands-on knowledge of:
• Preventive, predictive, and breakdown maintenance
• Mechanical and electrical maintenance practices
• Welding and cutting machinery
• Gearboxes, motors, pumps, compressors, and rotating equipment
• EOT cranes and material handling systems
• Fabrication machinery maintenance
• Maintenance planning and scheduling
• Spare parts planning and inventory management
• Root Cause Analysis (RCA)
• TPM, 5S, Kaizen, and Lean Manufacturing
• Machine installation and commissioning
• Equipment reliability and condition monitoring
• Heavy Engineering
• Pressure Vessel Manufacturing
• Process Equipment Manufacturing
• Oil & Gas Equipment
• Boiler Manufacturing
• Industrial Burners & Combustion Systems
• Steel & Metal Fabrication
• EPC Manufacturing
• Process Plants
• Industrial Machinery Manufacturing

Key Performance Indicators (KPIs):

Technical Competencies:

Preferred Industry Background:

Preferred Qualifications

• Additional certifications in Maintenance Management, TPM, Reliability Engineering, or Safety will be an added advantage.