Job Description

Overview:Purpose/ Key Role

• Up keeping Projects and Utility equipment and ensuring equipment availability at all times.
• Ensuring Volume compliance by ensuring reliability of all manufacturing lines.
• Ensuring Preventive Maintenance, Condition Based Maintenance, Breakdown & Shutdown Maintenance .
• Minimizing Scheduled and Unscheduled downtimes, reduction of breakdown hours inline with Aspirational targets of the Plant.
• Ensuring Ontime RCA closure and Red Tag Compliances
• Adherence to PepsiCo Maintenance Management guidelines
• Ensuring NIL loss in production due to non-availability of equipments, spares, lack of preventive and corrective maintenance
• Ensuring statutory and legal compliance.
• Implement safety standards and build safe working culture.
• Implement GMPs and best practices.
• Drive corporate agenda- TPM, Safety, AIB, Productivity, OHS.
• Ensuring timely & Safely execution of Projects.
• Knowledge about Spare & Service planning .
• Budget Control.

Responsibilities:Roles and ResponsibilitySafety

• Implement safety standards and drive safety culture.
• Participate in safety meetings and close the agreed recommendations within agreed timeline.
• Work with SHE pillar and safety coordinator on implementing the Safety related action points and working to ensure Zero LTA in the plant.
• Execute safety and sustainability capex and initiatives.

Sustainability

• Track, monitor and report sustainability KPIs.- EUR and WUR
• Drive sustainability agenda and take essential steps to achieve goals.
• Drive new sustainability project trials through continuous improvement

Operational Excellence

• Ensuring that all machine maintenance activities are carried out to minimize machine breakdowns
• Preparing schedule for machine maintenance (weekly, monthly and annual) from OEM manuals and list of requirements from respective departments
• Raising indents for spare parts and getting indents approved by the Plant Manager and Maintenance Manager
• Ensure Compliance with Global Control Systems and PR-PO process adherance
• Specifying manpower requirements for maintenance jobs to the respective department owners and coordinating with them about the same
• Interacting with the contractors for getting any breakdown related jobs done
• Doing hands-on repair work for machines at the time of electronics related breakdowns
• Prioritizing the maintenance jobs that have to be carried out for the machines
• Coordinating with production for timely release of machines for shut down activities/ preventive maintenance
• Sanctioning the replacement of high value spares after analyzing the breakdown cause and the need for replacement of the spare part.
• Monitoring the maintenance activities on regular maintenance days (Saturday of every week)
• Reviewing the maintenance activities at the end of the day and ensuring that all scheduled activities have been carried out
• Submitting a weekly machine efficiency report to the Plant Manager and the Engineering Manager
• Ensuring annual overhauling of all machines:
• R&M Budget Spends and Control as per the AOP [Annual Operating Plan]
• Planning for shutting down of machine for planned maintenance
• Supervising the fitter and electrician who carry out the actual overhauling
• Maintaining history sheets of overhauling and preventive maintenance schedules

Planned maintenance

• Preparing maintenance schedule for utility equipment- Boiler, ETP, Bio-methanation, WTP, Electrical distribution system.
• Plan resources to execute PM and share PM Compliance report monthly basis.
• Coordinate and align cross functional team for shutdown, Preventive and other maintenance jobs.
• Address red tags and plan for closure of red tags. Share monthly closure report.
• Prepare root cause analysis for failure and action planning.
• Identify bottlenecks and make action plan.
• Conduct AMC services as per plan and maintain documents.
• Maintain PM related documents- History card, check sheets, service reports, service contracts, agreements.
• Ensure proper utilization of resources.

R&M

• Prepare R&M budget for utilities.
• Monitor and control R&M, share monthly report.
• Drive initiatives for cost saving through local development/procurement, alternate cost-effective spares/ systems.
• Proactively highlight R&M expenses event basis.

VMOH

• Prepare AOP for power and fuel usage, R&M, Contractual Manpower deputation and optimization.
• Track and monitor power and fuel usage.
• Reporting power and fuel usage on daily basis.
• Preparing MIS on daily basis and ensure weekly submission to stores and commercial.
• Drive and implement Power and fuel saving initiatives and Kaizen.

Spare Management

• Define inventory level of spares and ensure availability of spares. Classification of spares w.r.t cost and criticality.
• Negotiate with vendors, suppliers, and service providers.
• Control stores inventory.
• Work closely with vendors on high cost / import substitute Spare parts development.
• Conceive, suggest and implement ideas regarding design and modification of existing equipment/spares for improved benefit.
• Support engineering stores in reducing inventory through analysis and acting on non-moving items

TPM

• Drive TPM Agenda.
• Analyzing collectively the problem taken up by the group
• Designing solutions/ suggestions to the specific projects/ problems taken up by the TPM
• Implementation of the solutions
• Internalizing the TPM culture
• Closely monitor the circle targets and driving the PM pillar action plan

Quality

• Support plant team in driving quality related initiatives- AIB, FSSA, etc.
• Close quality and food safety related observations raised by plant.
• Identifying areas of improvement and highlighting these to Quality Manager
• Implementing the action plans developed by the Quality Manager for continuous improvement.

People management

• Preparing shift schedule.
• Allocating resources, manpower based on the skill and competency.
• Conducting skill assessment for operatives, identify area of improvement.
• Conducting in-house /OEM technical trainings for technicians.
• Developing technicians through involving in projects and other initiatives.
• Conduct daily meeting addressing maintenance related issues and deriving action plan.
• Conduct a meeting with technician sharing engineering performance.

Project Management:

• Execute plant capex as per timeline and approved budget
• Preparing detailed project schedule & tracking the progress
• Selecting the best vendor after complete detailing & techno commercial analysis and getting it approved from commercial
• Ensuring and implementing Safe working practices during the entire project.
• Working with the plant team in designing & implementing proper food safety & hygiene standards for the projects
• Coordinate with cross functional team for seamless execution.
• Work closely with commercial & HR team to get the statutory compliances done for the project.
• Handover of the complete system with proper documentation to the plant team.
• Ensure the Purchase Order closure thru proper verification of job and the amount billed.

Statutory Compliances

• Prepare statutory calendar and ensure implementation.
• Electricity act, The Air (Prevention and Control of Pollution) Act, The Legal Metrology Act, The Explosives Act, The Petroleum Act, The Water (Prevention and Control of Pollution) Act, The Indian Boilers Act, The Factories Act,
• Conduct annual testing and certification of boilers as per IBR norms.

Learning

• Seeking feedback from seniors and peers
• Reflecting on own competencies and possible gaps
• Setting learning goals in consultation with seniors
• Monitoring implementation of these goals
• Continuously updating knowledge from outside environment
• Develop in-depth understanding of MIS, VMOH, MOR etc.

Qualifications:QualificationsBE/BTech in Mechanical / Electrical / Electronics / Electronics and Instrumentation with minimum 8-10 years of experience in a FMCG / Food industry desirable.

• Sound Process, Packaging equipment knowledge.
• Knowledge about PLC & automation.
• Improvement projects experience.
• Knowledge of Utilities HVAC, DG sets, Air Compressors, High pressure Boilers., Nitrogen Generation Plant, ETP and
• Good Communication and negotiation skills.
• Knowe ledge about Statutory compliance applicable for Electrical & mechanical equipments.

Additional information / Complexity

• Operating in largest food plant of Pepsico with 75000T capacity with 6 product lines and state of the art technology & largest manpower pool.
• Complexity to manage mixed age group of workmen with variable learning curve
• Complexity to manage delivery, cost & quality with challenging & variable input
• Managing operation of advanced technology platforms
• Keeping this plant productive & engaged and setting long term cultural framework of the plant for future success.

PepsiCo