PRODUCTION MAINTENANCE HEAD
Role Overview
Role: Production Maintenance Head
Location: Pune, Maharashtra, India – MIDC Chinchwad
Industry: Textile Manufacturing
Product: Adsorbent Cotton Pads, absorbent cotton, bleached cotton and cotton-based hygiene products
Role Status: New Role
Reporting To: Plant Head / Director – Operations
Shift Responsibility: Two shifts initially, with readiness to transition to three shifts at a later date
(The designation will be finalized based on the shortlisted candidate’s current profile, background, qualifications and experience following the interview and selection process)
About Company
The organization is a Pune-based, manufacturing company specializing in high-quality absorbent cotton, bleached cotton, and cotton-based hygiene products. With over two decades of industry experience, the organization serves international markets, including Japan, Germany, and Switzerland.
What makes this opportunity particularly interesting is its position as a specialized, quality-driven manufacturing organization with modern and automated facilities, international quality standards, and strong exposure to export markets. For candidates, this can be a valuable opportunity to gain hands-on experience across the complete manufacturing and quality processes, take ownership of key responsibilities, and grow within a focused and professionally managed organization.
The manufacturing facility is located in MIDC Chinchwad, Pune, while the registered office is located in Mumbai.
Position Summary
We are seeking an experienced, technically strong and result-oriented Production Maintenance Head to take integrated ownership of production operations and plant maintenance. The incumbent will be responsible for achieving the highest possible output and productivity while meeting production deadlines, maintaining product quality, ensuring machine and utility reliability, and complying with all applicable safety, statutory, hygiene, SOP and quality requirements.
The role combines production leadership with maintenance oversight for a highly automated manufacturing environment comprising 40+ machines (few German special machines), including PLC-controlled systems, VFDs, Servo Motors and other automated control systems, along with 7–8 compressors and the Utility Department. The role requires close coordination between Production, Maintenance, Quality and other functions to minimize downtime and ensure uninterrupted operations.
Scope of Responsibility
· Production workforce as of date: approximately 25 Operators, 35 Helpers and 10–12 Staff members.
· Production and maintenance responsibility for 40+ machines.
· Equipment exposure including PLC systems, VFDs, Servo Motors, sensors, instrumentation, electrical control panels, pneumatic systems and other automated equipment.
· Exposure to Rieter make machinery is preferred / an added advantage.
· Maintenance and utility responsibility for 7–8 compressors and the Utility Department + ETP etc..
· Round-the-clock utility and maintenance support to production, with a strong focus on zero breakdowns during operations.
Key Responsibilities
A. Production Leadership & Operations
· Lead and manage complete plant production activities across two shifts, with readiness for future three-shift operations.
· Own daily, weekly and monthly production targets and ensure timely fulfilment of production schedules and customer commitments.
· Drive optimum machine utilization, productivity and overall equipment effectiveness (OEE) while minimizing downtime, wastage and operational losses.
· Ensure the highest possible output while meeting deadlines and maintaining the required quality of product.
· Build a high-performance shop-floor team through effective leadership, training, motivation, discipline and skill development.
· Monitor attendance, manpower utilization, productivity and shift-wise performance.
· Identify production bottlenecks and implement process and productivity improvement initiatives.
· Coordinate closely with Planning, Quality, Procurement, Logistics and other functions for seamless plant operations.
· Analyse production data and prepare / review MIS covering productivity, efficiency, wastage, downtime and target achievement.
B. Maintenance Leadership & Reliability
· Lead and oversee the complete maintenance function for 40+ production machines.
· Ensure maximum machine availability, reliability and operational efficiency with minimum unplanned downtime.
· Plan and implement preventive, predictive, condition-based and corrective maintenance programs.
· Ensure effective maintenance planning and execution across all shifts without adversely affecting production commitments.
· Ensure rapid diagnosis and resolution of machine breakdowns and drive a zero-breakdown mindset during production operations.
· Conduct Root Cause Analysis (RCA) for recurring breakdowns and implement permanent corrective actions.
· Track and improve maintenance KPIs including Machine Availability, Plant Uptime, MTBF, MTTR, Breakdown Frequency and Preventive Maintenance Compliance.
· Coordinate with OEMs, vendors and technical service providers for specialized maintenance requirements, modifications and troubleshooting.
· Support installation, commissioning, stabilization and performance improvement of new machinery and automation projects.
C. Electrical, Electronics & Automation
· Demonstrate strong working knowledge of electrical and electronics systems used in automated manufacturing equipment.
· Troubleshoot and support PLC-based machine control systems.
· Handle / troubleshoot VFD drives and Servo Motor / Servo Drive systems.
· Understand electrical control panels, sensors, instrumentation, pneumatic systems and related machine-control components.
· Ensure timely identification of electrical, electronic, automation and control-system faults.
· Rieter machine exposure / maintenance knowledge will be an added advantage.
D. Utilities & Compressor Management
· Oversee the Utility Department and maintenance of 7–8 compressors + ETP etc..
· Ensure round-the-clock utility support to production operations.
· Maintain high reliability and availability of compressors and critical utilities, with a strong objective of zero breakdowns during operations.
· Plan preventive and predictive maintenance for compressors and utility systems.
· Monitor utility performance, energy consumption and opportunities for energy saving and cost optimization.
· Ensure safe operation and maintenance of utility equipment and compliance with applicable statutory and safety requirements.
E. Quality, Safety, Compliance & Documentation
· Ensure production output consistently meets defined quality requirements and export-oriented manufacturing standards.
· Work closely with Quality Assurance / Quality Control teams to reduce defects, rejections, wastage and customer complaints.
· Ensure adherence to SOPs, GMP, hygiene, safety, environmental and statutory requirements, as applicable.
· Promote a culture of safety, housekeeping, discipline and operational excellence.
· Ensure adherence to safe maintenance practices, including appropriate isolation / LOTO procedures.
· Maintain production and maintenance records, equipment history, SOPs, schedules and audit documentation.
F. Spares, Cost Control & Continuous Improvement
· Develop and maintain adequate critical spare-parts inventory covering electrical, mechanical, pneumatic and automation components.
· Monitor spare consumption and establish effective replenishment / reorder mechanisms.
· Optimize maintenance and manufacturing costs through effective manpower, machine, material, energy and inventory utilization.
· Drive TPM, Lean Manufacturing, OEE improvement, reliability improvement and continuous improvement initiatives.
· Identify opportunities for automation, process improvement, machine modification and cost optimization.
· Participate in CAPEX planning, equipment selection, technology upgrades and plant improvement projects.
Team Leadership
· Provide leadership to production and maintenance teams and establish clear accountability for output, quality, uptime and safety.
· Coordinate production supervisors / shift in-charges, maintenance technicians, electricians, automation personnel, utility operators and external service contractors as applicable.
· Plan manpower allocation, shift coverage and maintenance schedules.
· Build technical and operational capability through structured training and skill-development programs.
· Foster a culture of ownership, responsiveness, problem-solving and continuous improvement.
Desired Candidate Profile
Educational Qualification
· Bachelor’s Degree / Diploma in Textile Engineering, Textile Technology, Production Engineering, Mechanical Engineering, Electrical Engineering, Electronics Engineering, Instrumentation Engineering or a related discipline.
· Additional qualifications / certifications in Manufacturing Excellence, TPM, Reliability Engineering, Lean Manufacturing, Six Sigma, Automation or Maintenance Management will be advantageous.
Experience
· Typically 12–20+ years of relevant manufacturing / production / maintenance experience, with substantial leadership exposure.
· Strong experience in a plant-level Production and/or Maintenance leadership role.
· Textile manufacturing background is preferred. Experience in Textile, Non-Woven, Cotton Processing, Medical Textile, Hygiene Products, Technical Textile, Packaging, FMCG Manufacturing or other highly automated / machine-intensive manufacturing environments will be considered.
· Strong experience managing shop-floor teams and multi-shift manufacturing operations.
· Hands-on exposure to 30+ / 40+ automated production machines and maintenance management is strongly preferred.
Key Performance Indicators (KPIs)
1. Production Target Achievement
2. Machine Availability and Plant Uptime
3. Machine Utilization and OEE
4. Reduction in Downtime and Breakdown Frequency
5. MTBF Improvement and MTTR Reduction
6. Preventive Maintenance Compliance
7. Quality Compliance and Reduction in Rejection / Scrap
8. On-Time Delivery Performance
9. Workforce Efficiency
10. Maintenance and Manufacturing Cost Control
11. Energy Efficiency Improvements
12. Safety and Statutory Compliance
How to Apply
If your experience matches the above requirements and you are interested in this opportunity, please share your updated CV with answers to below queries to
[email protected]
A. Candidate Information Required
1. Total Years of Experience:
2. Relevant Experience:
3. Notice Period / Buyout Option:
4. How soon can you join if selected?
5. Current CTC + Variable:
6. Fixed CTC:
7. Expected CTC:
8. Genuine Reason for Job Change:
9. Current Location:
10. Native Place:
11. Current Designation:
12. Current Company Turnover:
13. Current Reporting Manager – Designation:
14. How many years of experience do you have in a Production Head / Production Manager / senior production leadership role with details?
15. How many years of experience do you have in Textile / Non-Woven / Cotton / Hygiene Products manufacturing? Please mention name of industries worked with details?
16. How many years of experience do you have managed a shop-floor workforce of 50+ employees, including Operators, Helpers, Supervisors and Staff with details?
17. How many years of experience do you have managing production operations across two or more shifts?
18. How many years of experience do you have managing 30+ production machines in an automated manufacturing environment with details?
19. How many years of experience do you have in OEE improvement, TPM, Lean Manufacturing, productivity improvement and downtime reduction?
20. How many years of experience do you have working with PLC, VFD, Servo Motors and other automated machine-control systems with details?
21. How many years of experience do you have ensuring production compliance with Quality, Safety, GMP/SOP and other manufacturing standards with details?
22. How many years of experience do you have in Maintenance Management within a manufacturing plants and Utility Management with details?