Head - Engineering & Maintenance

Irama Global Services

Responsibilities:

Engineering Standards, Processes and EHS systems

• To establish engineering standards, SOPs, design specifications, reliability guidelines and maintenance philosophies for all units.
• Put a system in place for compliance with statutory and regulatory norms , pressure vessels, static and rotary equipment, lifting equipment, building and structures, electrical safety, hazardous area classification, environmental regulations etc.
• Put a rigorous planning process in place for planning of spare parts to ensure 100% availability of identified spare parts.
• Apply methods such as ABC analysis and reliability-based stocking.
• Establish best practices such as TPM, RCM, FMEA and RBI and implement across the plants. To ensure technical audits and closure of observations (HSE, PSM, ISO, OEM, insurance).
• Ensure strict adherence to safe engineering practices, PSSR, MOC, PTW, LOTO, and overall Process Safety Management.
• To review and approve the Planned, Preventive and Predictive maintenance schedules for all equipment (Mechanical, Electrical & Instrumentation) according to vendors recommendations and industry best practices.
• Put system in place to ensure Zero Accidents in workplace including internal safety audits system.

Maintenance Planning & Asset Reliability, Performance Monitoring and Improvements :

• Establish targets continually improve high level OEE and achieve global benchmarks in reliability KPIs.
• Put a rigorous process in place for monthly review of the maintenance KPI performance , monitor OEE, MTBF, and to identify areas of improvements
• To monitor effectiveness of Preventive and Predictive maintenance programs and drive improvements.
• Develop and implement Asset Integrity Management System (AIMS) including inspection intervals, NDT planning, corrosion monitoring, vibration analysis, thermography and thickness measurement.
• Monitor and eliminate losses using TPM methodology. Drive reduction in unplanned downtime and Mean Time Between Failures (MTBF) improvement of critical assets
• Conduct proper RCA to solve reliability issues and track actions to closure.
• Drive continuous improvement initiatives such as energy optimisation, steam recovery, gypsum handling, acid concentration improvements, and granulation efficiency.
• Implement digital tools such as AI/ML, CMMS, DCS/PLC data analytics, historian systems and predictive analytics for decision-making.

Training, Skills and Talent Management :

• Identify the skills needed for implementation of the Maintenance Plan.
• Recruit the team with right level of skills and experience and put in place rigorous selection procedure.
• Ensure continuous training and development of the maintenance team so that they are up to date with current maintenance techniques, engineering standards, equipment maintenance requirements etc.
• Monitor performance of individuals and give them feedback on improvement areas and implement comprehensive performance review processes for their development.
• Ensure only high quality contractors are selected for maintenance services, fabrication, shutdown manpower, OEM support, and emergency support. Monitor their performance and provide continuous feedback for improvement.

Turnaround & Shutdown Management :

• To be responsible for the planning and execution of major turnarounds (TA), shutdowns and catalyst changeouts for SAP/PAP/DAP plants.
• To define the budgets, timelines, manpower planning, contractor management and quality control measures in discussion with the Manufacturing Head.
• Ensure shutdowns are completed safely, within timeline and cost, with reliable post-startup performance.
• To ensure department heads coordinate with Operations, Supply Chain, HSE and Projects for seamless shutdown execution.

Projects Engineering & Capex Execution

• To lead all brownfield and greenfield engineering projects including capacity expansion, debottlenecking, efficiency improvement and infrastructure upgrades.
• Prepare basic engineering, detailed engineering, equipment specifications, tender documents, technical evaluations, and vendor selections.
• To oversee project scheduling, budgeting, execution, supervision, commissioning and handover to operations.
• Collaborate with OEMs, technology licensors, EPC contractors and consultants.
• To ensure up to date engineering drawings, P&IDs, layouts, electrical SLDs, loop diagrams, asset registers and plant documentation.

Budgeting, Contracts & Vendor Management

• Prepare annual engineering budgets covering maintenance, spares, shutdowns and capital projects.
• Establish cost saving targets annually and monitor the progress.
• Monitor the spending on monthly basis and control the cost of maintenance.