Shift Incharge ( AM / DM ) - Mechanical Maintenance Planning - SMS

Purpose of the Role 
To plan, coordinate, and oversee all mechanical maintenance activities during the assigned shift in the Steel Melting Shop (SMS) operating on Electric Arc Furnace (EAF) technology. The incumbent will ensure plant availability, minimize unplanned breakdowns, drive systematic maintenance planning, and maintain accurate records through SAP HANA – covering Purchase Requisitions (PR), maintenance cost tracking, daily shift reporting, and Root Cause Analysis (RCA) for critical failures.

Job Responsibilities (KRA)
Shift Operations & Mechanical Maintenance 

• Lead mechanical maintenance shift operations for all SMS equipment including EAF, LRF, VD/VOD, CCM, and associated auxiliaries. 

• Monitor shift-wise equipment health and take proactive corrective action to prevent breakdown escalation. 

• Ensure timely and quality execution of planned preventive maintenance (PPM) schedules for critical rotating and static equipment. 

• Coordinate with production / shift supervisors for planned shutdown jobs, ensuring maintenance windows are effectively utilized. 

• Supervise maintenance contractors and internal tradesmen (fitters, welders, riggers) for safe and efficient job execution. 

• Ensure availability of critical spares at shop floor prior to planned jobs; coordinate with stores for emergency issues

Maintenance Planning 

• Prepare and update weekly and fortnightly mechanical maintenance plans for SMS equipment in alignment with production schedules. 

• Create and manage Work Orders (WO) in SAP HANA for all planned and unplanned maintenance jobs. 

• Track WO completion status, backlog maintenance jobs, and escalate pending critical jobs to the department manager.

• Coordinate job scheduling across shifts to ensure uniform load distribution and zero conflict with production targets. 

• Maintain equipment-wise maintenance history log and update in SAP HANA for future planning reference. 

• Ensure calibration and maintenance of critical measuring instruments and tools.

SAP HANA – PR, Work Orders & Cost Management 

• Raise Purchase Requisitions (PR) in SAP HANA for capital spares, consumables, and maintenance services based on planned requirements and reorder levels. 

• Monitor PR processing timelines and follow up with procurement/stores to ensure timely availability of critical materials. 

• Track and analyse maintenance costs at shift/monthly level through SAP HANA cost centre reports. 

• Ensure accurate posting of man-hours, material consumption, and service entries in SAP HANA for each Work Order. 

• Support budget preparation for the SMS maintenance department by providing historical spend data from SAP HANA. 

• Drive reduction in maintenance cost through planned vs reactive maintenance ratio improvement and spare life enhancement

Daily Reporting & MIS 

• Prepare and submit shift-end Mechanical Maintenance Report covering: 

           ◦ Equipment breakdown summary with downtime in minutes 

           ◦ Planned vs. actual maintenance job completion status 

           ◦ Critical observations, near-misses, and safety incidents 

           ◦ Manpower deployment vs. availability 

           ◦ Spare parts consumed vs. balance at shop floor 

• Compile and present the Daily Maintenance Review (DMR) data to the department manager including KPI tracking – MTBF, MTTR, OEE impact, and planned maintenance compliance (PMC). 

• Maintain and update equipment-wise daily health sheets, lubrication sheets, and vibration logs. 

• Submit cost monitoring reports as per SAP HANA extracts on a weekly/monthly basis.

Root Cause Analysis (RCA) 

• Lead RCA for all major/repetitive breakdowns in SMS – EAF, electrode regulation system, EAF shell, furnace tilting system, fume extraction system, CCM segments, mould oscillators, and casting platform equipment. 

• Apply structured RCA methodologies such as 5-Why Analysis, Fishbone (Ishikawa) Diagram, and FMEA. 

• Document findings, root causes, and corrective / preventive actions (CAPA) in SAP HANA Notification system. 

• Monitor closure of CAPA actions within committed timelines; present RCA findings in monthly review meetings. 

• Identify recurring failures and develop long-term reliability improvement actions to reduce breakdown frequency. 

• Coordinate with OEMs, vendors, and technical teams for specialized RCA support on critical failures.

Safety, Compliance & Housekeeping 

• Ensure strict compliance with plant safety norms – PTW (Permit to Work), LOTO, working at height, hot metal handling safety, and confined space entry protocols. 

• Conduct pre-shift safety briefings and toolbox talks for maintenance tradesmen. 

• Ensure zero unsafe acts and conditions in the shift; report and investigate near-misses immediately.

• Maintain 5S housekeeping standards in the maintenance workshop and EAF bay. 

• Comply with statutory and regulatory requirements related to boiler, pressure vessels, and crane maintenance.

Job Requirements (KPI)
Qualification: Diploma / B Tech -Mechanical
Experience: 6+ Years