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

About Zeeco:

Zeeco is a global leader in advanced combustion and environmental solutions, providing innovative products and services to the oil & gas, petrochemical, refining, power, and process industries. With manufacturing and engineering operations across the globe, Zeeco offers an opportunity to work on world-class industrial equipment while driving operational excellence and continuous improvement.

We are seeking an experienced Plant Maintenance professional to lead maintenance operations at our heavy fabrication manufacturing facility. This role is ideal for candidates passionate about equipment reliability, preventive maintenance, team leadership, and improving plant performance.

Qualification:

• Diploma / B.E. in Mechanical Engineering

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

• Proven hands-on experience with fabrication plant machinery, including welding/cutting setups, hydraulics, pneumatics, and cranes. Skilled in both mechanical and electrical preventive maintenance.

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.

Preventive & Predictive Maintenance:

• 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.

Equipment & Utilities Maintenance:

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

Reliability & Continuous Improvement:

• 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.

Planning & Coordination:

• 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.

Projects & Plant Expansion:

• 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.

Cost & Budget Management:

• 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.

Documentation & Compliance:

• 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.

Key Performance Indicators (KPIs):

• 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

Technical Competencies:

The ideal candidate should possess strong hands-on knowledge of:

• Preventive, predictive, and breakdown maintenance

• Mechanical and electrical maintenance practices

• Hydraulic and pneumatic systems

• 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

Preferred Industry Background:

• 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