Maintenance Manager – Electrical, Mechanical & Plant Utilities

About the Role

Celestix Industries is establishing a large-scale, greenfield manufacturing campus in Falna, Rajasthan, comprising multiple factories focused on electrical components, copper busbar manufacturing, wiring harness production, sheet metal fabrication and industrial manufacturing.

We are looking for a highly experienced, technically strong and hands-on Maintenance Manager / Maintenance Head to establish and lead the electrical, mechanical and industrial maintenance functions across the manufacturing campus.

This position is suitable for an experienced Maintenance Engineer, Plant Maintenance Manager or Industrial Maintenance professional who has progressed into a leadership role and possesses strong practical knowledge of manufacturing machinery, electrical systems, mechanical equipment, automation, plant utilities and maintenance management.

During the initial phase, the selected candidate will be responsible for planning maintenance infrastructure, reviewing machinery and utility requirements, supporting equipment installation, coordinating machine commissioning, establishing preventive maintenance schedules, identifying critical spare parts and developing the maintenance team.

Once production begins, the Maintenance Manager will assume responsibility for equipment availability, preventive and predictive maintenance, breakdown response, machine reliability, industrial utility systems, maintenance costs and continuous improvement.

The manufacturing campus is planned to include equipment and processes such as:

• CNC fiber laser cutting machines
• CNC press brake bending machines
• Copper busbar cutting, punching, bending and machining equipment
• Mechanical and hydraulic presses
• MIG, TIG and ARC welding equipment
• Wiring harness cutting, stripping and crimping machines
• Ultrasonic welding equipment
• Electrical and continuity testing equipment
• EOT cranes and industrial material-handling equipment
• Air compressors and pneumatic systems
• Electrical distribution systems and plant utilities
• Additional industrial machinery as manufacturing operations expand

The most important requirement is the ability to independently manage electrical and mechanical maintenance while establishing reliable preventive maintenance and breakdown-control systems for a new multi-factory manufacturing operation.

This is not a desk-only maintenance management position. The candidate must be comfortable working directly with maintenance engineers, electricians, fitters, technicians, production supervisors, equipment manufacturers and external service providers.

Key Responsibilities

1. Greenfield Plant Maintenance Setup & Commissioning

The Maintenance Manager will play a central role in establishing maintenance systems and supporting the commissioning of the new manufacturing campus.

Responsibilities include:

• Review manufacturing machinery, utility and maintenance requirements before production starts.
• Participate in technical discussions involving machine installation and commissioning.
• Review machine installation drawings, equipment specifications and utility requirements.
• Coordinate electrical, mechanical, pneumatic and hydraulic installation readiness.
• Support planning of machine foundations, alignment, access and maintenance clearances with qualified engineering teams.
• Coordinate equipment installation schedules with Project, Production and Engineering departments.
• Participate in machinery trials, site acceptance testing and commissioning activities.
• Verify equipment documentation, operating manuals, recommended spares and maintenance instructions.
• Establish equipment identification and maintenance asset registers.
• Prepare preventive maintenance schedules before commercial production.
• Identify tools, testing instruments and workshop equipment required by the maintenance team.
• Coordinate OEM training for maintenance personnel.
• Ensure major commissioning defects and equipment deficiencies are recorded and resolved.
• Establish procedures for transitioning newly commissioned equipment into regular maintenance operations.

The Maintenance Manager should help ensure that machinery is safe, maintainable and reliable before it is handed over to the Production department.

2. Electrical Maintenance & Troubleshooting

Lead electrical maintenance activities for industrial manufacturing machinery and associated electrical systems.

Responsibilities include:

• Supervise electrical troubleshooting and maintenance of manufacturing equipment.
• Diagnose electrical breakdowns and coordinate effective corrective action.
• Understand industrial control panels, wiring diagrams and electrical schematics.
• Maintain electrical motors, motor starters, contactors, relays and protection devices.
• Troubleshoot variable frequency drives (VFDs), soft starters and motor-control systems.
• Support troubleshooting of sensors, limit switches, proximity sensors and electrical interlocks.
• Coordinate maintenance of machine control wiring and electrical connections.
• Monitor recurring electrical faults and implement permanent corrective actions.
• Ensure appropriate electrical inspection and testing procedures.
• Coordinate electrical maintenance with Production and authorized electrical personnel.
• Maintain proper electrical maintenance records.

The candidate should have practical experience with industrial electrical systems and the ability to guide technicians through structured fault diagnosis.

3. Mechanical Maintenance & Industrial Equipment

Manage mechanical maintenance of manufacturing equipment, including:

• Mechanical power presses
• Hydraulic presses
• CNC machine mechanisms
• Gearboxes and drive systems
• Bearings and shafts
• Linear guides and motion systems
• Conveyors
• Mechanical fixtures and handling equipment
• Industrial pumps
• Hydraulic power units
• Pneumatic cylinders and actuators
• Other production machinery

Responsibilities include:

• Diagnose abnormal vibration, noise, wear, misalignment and mechanical failures.
• Coordinate mechanical repairs and replacement of defective components.
• Monitor bearings, guides, couplings, lubrication systems and mechanical assemblies.
• Establish appropriate lubrication and inspection schedules.
• Ensure machine alignment and operating condition are maintained.
• Coordinate equipment overhauls and planned shutdown maintenance.
• Monitor recurring mechanical breakdowns and identify root causes.
• Ensure mechanical safety devices and protective systems are maintained.
• Coordinate specialist repairs with equipment manufacturers when required.

4. CNC Laser Cutting Machine Maintenance

Provide maintenance leadership for CNC fiber laser cutting equipment used in sheet metal fabrication.

Responsibilities include:

• Understand the major electrical, mechanical, pneumatic and control systems associated with CNC fiber laser machines.
• Coordinate preventive maintenance according to manufacturer recommendations.
• Monitor machine axis movement, drives, sensors and positioning systems.
• Coordinate maintenance of cutting-head mechanisms and approved consumables.
• Monitor chiller performance and machine cooling requirements.
• Ensure assist gas supply systems operate reliably.
• Diagnose machine alarms and support structured troubleshooting.
• Identify faults affecting cutting accuracy, machine availability and production consistency.
• Coordinate specialist laser-source, optical and controller maintenance with authorized OEM personnel.
• Maintain machine maintenance and breakdown records.

Direct experience with CNC fiber laser equipment is highly desirable.

5. CNC Press Brake & Sheet Metal Machinery Maintenance

Manage maintenance activities for CNC press brake machines and associated fabrication equipment.

Responsibilities include:

• Maintain hydraulic, electrical and mechanical systems of press brake machinery.
• Understand CNC back gauge mechanisms and positioning systems.
• Coordinate inspection of hydraulic pumps, valves, hoses and cylinders.
• Monitor machine alignment, motion accuracy and mechanical wear.
• Diagnose electrical and control-system alarms.
• Support troubleshooting of motors, drives, encoders, sensors and limit switches.
• Coordinate preventive maintenance according to machine manufacturer recommendations.
• Monitor abnormal machine movements and mechanical operating conditions.
• Ensure machine guarding and safety systems remain functional.
• Coordinate with OEM service personnel for specialized controller repairs.

Knowledge of CNC press brakes, mechanical presses and hydraulic equipment will be valuable for this position.

6. Copper Busbar Manufacturing Equipment Maintenance

Support manufacturing reliability in the copper busbar production division.

Equipment may include:

• Copper cutting and shearing machines
• CNC punching equipment
• Copper bending machines
• Hydraulic busbar processing machines
• Drilling and tapping machines
• CNC machining equipment
• Deburring and finishing equipment
• Material-handling and processing systems

Responsibilities include:

• Establish equipment-specific maintenance schedules.
• Monitor hydraulic, electrical and mechanical systems.
• Coordinate machine alignment and motion-system maintenance.
• Maintain equipment reliability and production accuracy.
• Identify recurring machine breakdowns and their causes.
• Coordinate maintenance of production machinery and related systems.
• Ensure critical machine spares are available.
• Work with Production to minimize machine downtime and avoidable material rejection.

7. Wiring Harness Manufacturing Equipment Maintenance

Manage maintenance support for the wiring harness and cable assembly manufacturing division.

Equipment may include:

• Automatic wire cutting and stripping machines
• Crimping presses
• Terminal applicators
• Pneumatic crimping equipment
• Wire twisting machines
• Ultrasonic welding equipment
• Soldering equipment
• Assembly conveyors
• Continuity testers
• Electrical testing equipment

Responsibilities include:

• Ensure equipment reliability and preventive maintenance.
• Monitor machine operating condition and recurring breakdowns.
• Coordinate mechanical, electrical and pneumatic troubleshooting.
• Support maintenance of crimping presses and associated mechanisms.
• Coordinate equipment repairs affecting cutting and stripping accuracy.
• Maintain automated machine sensors, controls and motion systems.
• Coordinate ultrasonic welding equipment maintenance with authorized specialists.
• Ensure test equipment faults are identified and rectified.
• Work with Production and Quality to prevent machine-related manufacturing defects.

Production tooling adjustment, process settings and product inspection remain under the relevant authorized Production and Quality teams.

8. Welding Equipment & Fabrication Machinery Maintenance

• Coordinate maintenance of MIG/MAG welding machines.
• Maintain ARC/Stick welding equipment.
• Support TIG and other welding equipment where installed.
• Inspect welding power sources, cables, connections and wire-feed systems.
• Coordinate maintenance of welding fixtures and positioners.
• Diagnose equipment-related welding interruptions.
• Maintain fabrication machinery and related utilities.
• Coordinate scheduled maintenance and equipment servicing.
• Support safe operation of welding equipment through appropriate equipment inspections.

9. EOT Crane & Heavy Material Handling Equipment Maintenance

The Falna manufacturing campus is expected to require heavy industrial lifting equipment, including EOT cranes.

The Maintenance Manager must understand the importance of reliable and safe lifting equipment.

Responsibilities include:

• Establish maintenance schedules for EOT cranes and associated lifting systems.
• Coordinate inspections of hoists, brakes, drives, limit switches, controls and other crane components.
• Monitor electrical and mechanical operating condition.
• Coordinate inspections and servicing of wire ropes, hooks, lifting accessories and safety devices as applicable.
• Ensure crane maintenance activities are performed by competent, authorized personnel.
• Coordinate OEM servicing and specialist repairs.
• Maintain statutory inspection, testing and certification records as applicable.
• Ensure equipment is removed from service when unsafe conditions are identified.
• Coordinate crane downtime and planned maintenance with Production.
• Support safe commissioning and operational handover of lifting equipment.

Experience with EOT crane maintenance is strongly preferred.

The Maintenance Manager will coordinate qualified specialists for statutory inspection, testing, certification and repairs requiring specialist authorization.

10. Plant Electrical Distribution & Power Systems

Manage maintenance coordination for electrical distribution infrastructure and associated industrial power systems.

Responsibilities include:

• Support commissioning and operational readiness of plant electrical distribution.
• Coordinate maintenance of LT electrical panels, distribution boards and motor-control centres.
• Work with authorized electrical engineers and contractors on HT systems where installed.
• Coordinate maintenance of transformers, switchgear and protective equipment.
• Support preventive inspections and testing of electrical distribution systems.
• Monitor electrical power quality and recurring utility interruptions.
• Coordinate maintenance of earthing and electrical protection systems.
• Support DG sets, UPS systems and backup power arrangements where installed.
• Ensure electrical maintenance work follows applicable safety procedures.
• Maintain inspection and maintenance records.

HT switching, statutory electrical work and other regulated activities must be carried out by appropriately qualified and authorized personnel.

11. Air Compressors, Pneumatic Systems & Industrial Utilities

Ensure reliable operation of plant utility systems, including:

• Air compressors
• Compressed air distribution
• Air dryers and filters
• Pneumatic systems
• Cooling water systems
• Industrial chillers
• Pumps
• Ventilation systems
• DG sets and backup power equipment, where installed
• Other production-critical utilities

Responsibilities include:

• Develop preventive maintenance schedules for utility equipment.
• Monitor utility equipment operating condition.
• Identify compressed air leakage and abnormal energy consumption.
• Monitor utility breakdowns and coordinate repairs.
• Maintain appropriate servicing and inspection schedules.
• Coordinate with suppliers regarding utility equipment maintenance.
• Ensure critical production equipment receives reliable utility support.

12. PLC, VFD, Sensors & Industrial Automation

The candidate should have practical understanding of industrial automation and control systems.

Responsibilities include:

• Understand PLC-based machinery control systems.
• Interpret electrical control drawings and PLC-related fault information.
• Support troubleshooting of PLC inputs, outputs and field devices.
• Diagnose sensor, relay, contactor and interlock faults.
• Support troubleshooting of VFDs, servo drives and associated systems.
• Coordinate CNC controller and HMI-related fault diagnosis.
• Maintain appropriate backups of approved control programs and machine parameters.
• Coordinate specialist programming or controller modifications with authorized engineers and OEMs.
• Ensure control-system changes are documented and validated before machine restart.

Hands-on troubleshooting experience with Siemens, Mitsubishi, Delta, Allen-Bradley, Fanuc or similar industrial control systems will be an advantage.

13. Preventive, Predictive & Breakdown Maintenance

Establish an organized maintenance management system for the manufacturing campus.

Responsibilities include:

• Develop equipment-specific preventive maintenance schedules.
• Establish daily, weekly, monthly and annual maintenance plans.
• Implement condition-based maintenance where appropriate.
• Coordinate vibration monitoring, thermography, lubrication analysis or other predictive techniques where beneficial.
• Establish breakdown reporting and escalation procedures.
• Minimize unplanned equipment downtime.
• Review recurring failures and implement corrective action.
• Maintain records of inspections, servicing, repairs and equipment condition.
• Coordinate planned maintenance shutdowns with Production.
• Monitor maintenance completion and overdue activities.
• Ensure maintenance plans are updated based on equipment performance and OEM recommendations.

14. Breakdown Analysis, Root Cause Analysis & Equipment Reliability

• Respond promptly to production-critical equipment breakdowns.
• Prioritize repair work according to safety, production impact and equipment criticality.
• Guide maintenance technicians in identifying faults.
• Apply systematic troubleshooting methods rather than repeated temporary repairs.
• Conduct root cause analysis for major and recurring breakdowns.
• Establish corrective and preventive actions.
• Monitor equipment failure trends.
• Improve Mean Time Between Failures (MTBF).
• Reduce Mean Time To Repair (MTTR).
• Improve machine availability and Overall Equipment Effectiveness (OEE).
• Coordinate engineering improvements where recurring design or installation problems are identified.

15. Maintenance Team Recruitment, Training & Leadership

• Develop maintenance manpower requirements for different manufacturing divisions.
• Recruit and lead electrical engineers, mechanical engineers, electricians, fitters and maintenance technicians in coordination with HR.
• Establish team responsibilities and shift coverage.
• Allocate maintenance jobs according to skill and urgency.
• Train employees in machinery maintenance and safe work procedures.
• Develop skill matrices and technical training plans.
• Coordinate specialist machine training with equipment suppliers.
• Monitor technician performance, productivity and response times.
• Develop maintenance supervisors and team leaders as the campus expands.
• Maintain strong communication with Production Managers and department heads.

16. Maintenance Spare Parts & Inventory Control

• Develop a list of critical and recommended machine spares.
• Establish minimum and maximum inventory levels for critical spares.
• Coordinate purchasing of approved spare parts and consumables.
• Maintain traceability of equipment-specific replacement parts.
• Identify long-lead-time spares that could affect machine availability.
• Avoid unnecessary inventory accumulation.
• Maintain maintenance consumable usage records.
• Coordinate with Stores and Procurement regarding stock availability.
• Monitor spare-part quality, supplier support and maintenance expenses.

17. Maintenance Planning, Budgeting & Cost Control

• Prepare annual and periodic maintenance budgets.
• Monitor maintenance labour, spare parts and service costs.
• Plan periodic equipment overhauls and major repairs.
• Review maintenance contracts and equipment service agreements.
• Evaluate repair-versus-replacement decisions.
• Identify cost-saving opportunities without compromising safety or reliability.
• Coordinate maintenance expenditure approvals.
• Support machinery CAPEX planning and future expansion requirements.
• Monitor external service provider costs and performance.

18. ERP, CMMS & Maintenance Documentation

Establish reliable maintenance records using ERP, Computerized Maintenance Management Systems (CMMS) or approved company systems.

Responsibilities include:

• Maintain an equipment asset register.
• Create preventive maintenance schedules.
• Record maintenance work orders.
• Maintain breakdown histories.
• Record spare parts usage.
• Track equipment downtime.
• Monitor maintenance expenditure.
• Maintain machine manuals and technical drawings.
• Record equipment service and calibration requirements.
• Support reporting and review of maintenance KPIs.

19. Manufacturing Safety, LOTO & EHS Compliance

• Ensure maintenance personnel follow approved safety procedures.
• Implement appropriate Lockout/Tagout (LOTO) and isolation practices.
• Ensure electrical equipment is safely isolated before authorized maintenance work.
• Follow safe practices for hydraulic, pneumatic and stored-energy systems.
• Coordinate safe maintenance of EOT cranes and lifting equipment.
• Ensure machine guards and safety interlocks are restored and verified before equipment handover.
• Enforce appropriate PPE requirements.
• Support permit-to-work systems for hazardous maintenance activities.
• Maintain safe practices for working at height, confined spaces and hot work where applicable.
• Coordinate incident and near-miss investigation with EHS.
• Ensure maintenance activities follow applicable statutory and equipment requirements.

20. Maintenance KPIs & Management Reporting

Develop and maintain maintenance performance reports covering:

• Equipment availability
• Breakdown frequency
• Unplanned downtime
• Preventive maintenance completion
• Mean Time Between Failures (MTBF)
• Mean Time To Repair (MTTR)
• Overall Equipment Effectiveness (OEE), in coordination with Production
• Critical equipment failures
• Spare parts consumption
• Maintenance cost
• Repeat breakdowns
• Maintenance backlog
• Critical utility interruptions
• Safety observations and corrective actions

Prepare regular maintenance reports for the Plant Head and company management.

21. Continuous Improvement, TPM & Reliability Development

• Implement practical Total Productive Maintenance (TPM) initiatives.
• Establish operator-level routine equipment care in coordination with Production.
• Improve maintenance response and troubleshooting procedures.
• Identify recurring failures and permanently eliminate their causes.
• Reduce maintenance-related production losses.
• Improve spare parts availability and maintenance planning.
• Support machine upgrades, reliability improvements and suitable automation.
• Implement 5S in maintenance workshops and spare-part storage areas.
• Develop a preventive maintenance culture rather than relying primarily on breakdown repairs.

22. Coordination With Production, Projects, Quality & Equipment Suppliers

• Work with the Plant Head on factory commissioning and operational readiness.
• Coordinate with Production Managers on equipment breakdowns and maintenance schedules.
• Work with Engineering on equipment modifications and manufacturing process improvements.
• Coordinate with Quality when machine problems affect product characteristics.
• Work with Purchase and Stores on critical maintenance spare parts.
• Coordinate with EHS on safe maintenance practices.
• Manage technical service coordination with OEMs and external contractors.
• Support machinery upgrades and future manufacturing capacity expansion.

Required Experience

• 8–15 years of industrial maintenance experience in a manufacturing environment.
• At least 3 years in maintenance leadership, supervision or departmental management.
• Strong practical knowledge of electrical and mechanical maintenance.
• Experience managing maintenance of production machinery and industrial utilities.
• Hands-on understanding of motors, drives, sensors, hydraulics, pneumatics and machine control systems.
• Knowledge of preventive, predictive and breakdown maintenance.
• Experience troubleshooting complex manufacturing equipment.
• Ability to guide electricians, mechanical technicians and maintenance engineers.
• Experience preparing maintenance schedules, monitoring downtime and managing critical spares.
• Knowledge of maintenance safety, electrical isolation and LOTO.
• Strong problem-solving, technical documentation and team-management ability.
• Experience coordinating machine manufacturers and external maintenance specialists.

Strongly Preferred Experience

• Greenfield plant setup or manufacturing equipment commissioning.
• CNC machine maintenance.
• Industrial automation, PLC and VFD troubleshooting.
• Electrical distribution and industrial utility maintenance.
• EOT crane and heavy material-handling equipment maintenance.
• Mechanical and hydraulic press maintenance.
• Sheet metal fabrication equipment maintenance.
• Electrical component or wiring harness manufacturing equipment.
• Maintenance ERP or CMMS implementation.
• TPM, MTBF, MTTR, OEE and root cause analysis.

The candidate does not need specialist-level expertise with every machine type, but must be capable of leading qualified maintenance personnel and coordinating OEM support across diverse manufacturing equipment.

Preferred Industry Background

Candidates from the following industries may be considered:

• Automotive component manufacturing
• Precision metal fabrication
• Sheet metal manufacturing
• Electrical component manufacturing
• Wiring harness and cable assembly manufacturing
• Copper busbar manufacturing
• Industrial machinery manufacturing
• Heavy engineering and fabrication
• Switchgear manufacturing
• Multi-process industrial manufacturing

Experience managing multiple manufacturing processes or a large industrial plant will be particularly valuable.

Qualifications

• B.E. / B.Tech in Electrical, Mechanical, Mechatronics or a related Engineering discipline.
• Diploma in Electrical or Mechanical Engineering with extensive relevant maintenance and leadership experience may also be considered.
• Additional training in industrial automation, PLCs, maintenance management or plant utilities will be an advantage.

Hands-on troubleshooting capability and proven maintenance leadership are more important than academic qualifications alone.

Ideal Candidate

We are looking for someone who can join a new manufacturing project, establish a practical maintenance department and ensure equipment remains reliable as production expands.

For example, when the factory receives a CNC laser cutting machine, a CNC press brake, a copper busbar processing machine and an EOT crane, the candidate should be capable of:

• Reviewing equipment installation and utility requirements.
• Coordinating with suppliers during installation and commissioning.
• Identifying machine-specific maintenance requirements.
• Ensuring appropriate service access and maintenance infrastructure.
• Preparing critical spare-part lists.
• Developing preventive maintenance schedules.
• Training the maintenance team on routine checks and fault diagnosis.
• Establishing breakdown escalation and equipment handover procedures.
• Maintaining equipment history and inspection records.
• Coordinating OEM support for specialized faults.
• Monitoring machine availability and maintenance costs.
• Ensuring safe and reliable operation during regular production.

We are not looking for someone whose experience is limited to supervising general building maintenance or arranging repairs through outside contractors.

The ideal candidate should have genuine hands-on factory maintenance knowledge and the ability to build an effective maintenance organization from the ground up.

What Success Looks Like

A successful Maintenance Manager will establish a maintenance function where:

• Machinery commissioning is supported effectively.
• Equipment asset registers and maintenance documentation are complete.
• Preventive maintenance schedules are established before regular production.
• Electrical, mechanical and utility failures are resolved efficiently.
• Repeated breakdowns are systematically reduced.
• Critical spares are available when needed.
• Maintenance activities are coordinated with Production.
• CNC machinery, presses, welding equipment and wiring harness equipment remain reliable.
• EOT crane maintenance and inspections are properly coordinated.
• Utilities remain available for production.
• Maintenance costs are monitored and controlled.
• Equipment downtime is accurately reported.
• Qualified technicians are trained and supervised.
• Safety procedures and statutory requirements are followed.
• Manufacturing capacity can expand without excessive maintenance-related downtime.

This role offers the opportunity to establish and lead the maintenance operations of a growing industrial manufacturing campus at Celestix Industries in Falna, Rajasthan.