Asahi India Glass - Department Head - Maintenance

Role Name : Department Head - Maintenance

Reporting To : Plant Head

Role purpose : To Ensure smooth & efficient functioning of Maintenance Dept.

Document created by : March, 2021

Responsibilities :

Heads : KRA (Key Result Areas) Dept . Head & KPI (Key Performance Indicators)

KRA (Key Result Areas) Dept . Head

Safety :

- To prepare Annual safety plan

- Review & monitor implementation of Annual Saftey Plan

MIS :

1. AMC charges of Utility

2. Repair and Maintenance Cost for plant ,

3. Improvement and Capital expenditure

4.Maintenance spares for plumbing,

5.Capital Expenditure

6. Review of manpower

7. Bech mark of All KPI

Budget Control :

1) To track monthly performance for each Kips against annual budget targets

2) Review of Target Control plan to Achieve R & M cost.

3) Generation of actual monthly report against Budget for Store issue ,Purchase class & Service charges

Maintenance (Plant & Machines) :

- To keep all equipments healthy condition by continues monitoring

- Review of Target Control plan to achieve breakdown

- Review of Preventive Maintenance plan and actual execution

- Review of Critical & consumable spares

- Plan & execute AMC of utility

- Review of Material handling operations & diesel consumptions.

- Review of Counter measure implementation as per analysis

Maintenance (Utility equipments) :

- Finalize and approval for annual maintenance contract

- Finalize and approval for Improvement activities of Utility

- Water Consumption Monitoring and reviewing/eliminating wastages

Improvement & Execution projects :

1. To plan, execute & monitor the construction of new buildings as per our layout.

2. To facilitate & execute installation of new machines.

3. To planning, execute & monitoring the improvement activities with user dept

Support to production :

- Review and approve improvement initiatives to enhance available time of machine and to reduce cycle time

- Review of process and plan for improvement to achive OEE

- Plan with prodcution persons to achive highest production

- Reduction in Utilty like power ,air ,water

Quality Management :

- To make dep't manual as per quality system

- Review and ensure compliance to TS16949, ISO - 14001,OSHAS ,TQM & TPM systems

Cost Reduction :

- Plan & review to initiate new cost reduction activities

- Review of altrnate source of high value spares

- Review of Inventory norms to minimize the inventory cost

- Review of manpower

Inventory :

- To track & control spare inventory to minimise inventory cost

- Review of high value spares by alternate spares developed locally .

- Finalize and approval for improvement activities as per CFT recommendation

Power :

- Revision of machine wise Power kwh /sq.mtr bech mark target

- Summarize all Utlity power consumption .

- Review of power targets And action plan to reduce

- Plan and Execute energy conservation to achive targets

Manpower Development :

- Identify training needs of staff

- Implementation of Performance Management & Deployment Management system.

- Total employees involvement

- To build up and maintain high morale and motivation in department members

KPI (Key Performance Indicators) :

Safety :

- Safety performance index

- Safety audit score

MIS : Gap Analysis

Budgeting : Timeliness of budgets submission

Budget Control : Timeliness Review and variance and action plan reporting

against budget

Maintenance (Plant & Machines) :

- Trend of Break down time & Frequency

- Plan V/S Actual gap against improvement plan

- No. of planned maintenance delay from schedule

Maintenance (Utility equipments) :

- Plan for Utilty reduction

- Plan V/S Actual gap against improvement plan

- No. of planned maintenance delay from schedule

Improvement & Execution projects :

1) Timeliness of budgets submission Plan v/s actual

2) Completion of project plan Vs actual

3) Cost budget vs actual

Support to production :

- Trend of Break down time & Frequency

- Plan V/S Actual gap against improvement plan

- No. of planned maintenance delay from schedule

Quality Management :

- TQM Audit score

- No. of NCR's in external audits.

Cost Reduction :

Trend of :

- R & M cost( Plant )

- Utility energy consumption

- Inventory Cost

Inventory :

- Maintain Inventory within budget

Power: To ensure power targets should be within limit

Manpower Development :

- Competency mapping score

- Training hours plan vs. actual

Manpower Development :

- Number of QC circles

- Number of PDCA's

- Iteration rate in the department

REQUIREMENTS :

Knowledge : Fair knowledge of Maintenance management practices

Experience (Number of years) : 15-18 yrs

Skills : Managerial, Communication, 360'Leadership and motivation

Qualification : Qualification B.E. ( Electrical/Mechanical )

INTERACTION :

- Internal Customers

- Other External parties/Vendors

- All Depts. Production, PPC & QA All spares & Service provider