Engineering Service Manager

Job Description

The Engineering Service Manager will be the driver of excellence when it comes to the overall engineering and maintenance activity of the factory. The person will be a proactive individual with many years’ engineering experience and proven leadership skills. You will be responsible for the overall operations of all process in the factory. Managing spare part inventory and ensuring uptime for all equipment will be a key deliverable. You will require exceptional foresight, great communication skills, and an aptitude for managing risk. Ideally, candidates will have proof of their supervisory and technical skills, and an appreciation for the complex nature of the industry. You will also be required to drive health and safety policies within the system.
 

1. Ensure adequate Operation of Air Compressors, Boreholes, Water Treatment Plants, Diesel Power Generators, 33KV and 11KV Feeders, Transmission lines from National Grid and Fire Hydrant Equipment to generate, treat and deliver Air, Water and Electricity at required pressures and quality
2. Ensure Monitoring of utility equipment performance and state on hourly basis and keep record of observations
3. Inspect and maintain Air Conditioners, refrigerators and ice machines, and chilled water supply systems.
4. Ensure equipment inspections are carried out according to standard checklists and report same on shift basis
5. Coordinate preventive maintenance tasks on air, water, hydrant and steam facilities on the shop floor and site general
6. Facilitate prompt action to correct leakages or deformations on all utility pipelines
7. Plan and support external inspector to achieve smooth and detailed statutory inspections on utility equipment from time to time
8. Support external assigned vendors on implementation of AMCs on all utility equipment
9. Drive utility capex.
10. Performs other related duties as assigned.

Key Deliverables

1. Run water facilities to deliver minimum of 6 bar G for process applications and 4 bar G for site applications; hydrant facilities to deliver minimum 8 bar G across site and compressed air to deliver 6 bar G for process applications
2. Make sure utility machine faults are attended to on time and no job repetition
3. Keep an update of all utility equipment on SAP and update all task list on SAP
4. Check and maintain daily utility maintenance record book and on system.
5. Lead and manage a team of Generator Operators in achieving 100% Diesel Generator availability.
6. Align with OEM to implement
7. Execute preventive maintenance program on all utility equipment using SAP.
8. Coordinates Preventive and Corrective Maintenance on Air Conditioning units across the site
9. Ensure water quality analyses are done and reported on shift basis; taking appropriate steps for immediate correction of deviations
10. Attends promptly to calls from production floor on any utility issues during production
11. Ensures all Lighting units on site are adequate maintained and catered for
12. Proactively inform the Chief Engineer on utility spare parts inventory

Strategic Effectiveness

1. Generate & implement a comprehensive engineering plan for the factory 
2. Implement preventive & corrective maintenance system for all the equipment, ensuring maximum up-time for all the equipment.
3. Generate and adhere to R&M budget & CAPEX proposals.
4. Create daily/weekly/monthly engineering reports, monitor operations and plant health
5. He has to interface effectively with Plant Operation & Maintenance team & agree on Utility KPIs & work towards achieving the same
6. Drive a team comprising of Operators & technicians to maximize the availability and running at optimum efficiency of Utility systems.
7. Ensure optimal inventory of running spares are maintained in store and managed through SAP.
8. Ensure all relevant EHS & statutory standards applicable for Utilities are followed
9. Work towards ideation, detailed engineering, approvals & execution of energy efficiency improvement projects
10. Accountable to organize and implement all planned maintenance activities on time for all utilities
11. Ensure breakdowns are attended promptly without and any interruption is duly communicated & aligned with the plant team
12. Ensure all relevant documentation is maintained such as Equipment layouts, PFDs, P&IDs, KPI trackers, RCAs etc for reference & easy retrieval.
13. Actively involve in RCA processes for utility lines failures
14. Maintain a professional relationship with OEMs on equipment upgrade and best preventive maintenance practices.
15. Ensure process equipment’s operates in accordance with safety standards and specification of OEM and local laws.

Operational Effectiveness

1. Always ensure that all jobs are carried out safely
2. 100% compliance on LOTO for any energy isolation
3. Always follow the safety norms and safety permits and keep them updated
4. Give safety orientation to all workers from time to time
5. Use appropriate PPEs while carrying out jobs
6. Ensure all the working areas are clean all the time
7. Maintain 5S norm in all utility work areas
8. Coordinate with safety and quality team for execution of all planned task.
9. Shows responsibility for safety of third-party employees.
10. Ensure other staff and parties work conform with all safety rules
11. Safe disposal and management of hazardous waste and other by-product.

Organizational Effectiveness

1. Maintain a high level of OEE for overall plant
2. Downtime analysis, optimizing the maintenance process for better utilization of resources.
3. Spare parts inventory management (Maintain an adequate level of spare parts as a cost-effective system). Building a network of JIT suppliers for cost control.
4. Process optimization and regular improvements. Leading quality initiatives and ensuring actionable information is captured at every process.
5. Strong follow-up for LT/HT electrical installations (existing) for proper maintenance
6. Monitoring of gen-sets, boilers, chillers, air compressors, WTP, ETP daily for energy-efficient operation

Requirements

1. 5 years in Engineering services, utility operation and maintenance experience in the manufacturing sector
2. Should be able to collect data and make reports
3. Good technical insight and able to trouble shoot simple & complex technical issues
4. Team player
5. High sense of Quality & safety consciousness
6. Hands on experience in various process equipment, electrical systems and Utility equipment.
7. Computer proficiency is required
8. Able to read and interpret vendors manuals and drawings
9. Ability to make electrical designs relevant to the plant systems is required
10. Able to communicate clearly and effectively with the personnel, contractors, vendors OEM suppliers and management.
11. Demonstrate ability to be proactive in problem solving and to lead the resolution of equipment problems.
12. Ability to lead, coach and train.