Manikaran Power Limited
Website:
manikaranpowerltd.in
Company:
https://www.linkedin.com/company/manikaran-power-ltd
Industries: Services for Renewable Energy and Electric Power Generation
Job details:
Position- Maintenance Head – BESS Assembly Line
Role Purpos
eThe Maintenance Head will own equipment reliability and process uptime for the BESS prismatic pack and container assembly line, starting from Design Approval (DAP) through installation, commissioning, and full-scale production. This is a hands-on leadership role requiring deep technical command of automation, controls, mechanical systems, and utilities, along with the ability to build and lead a maintenance function from the ground up and operate independently with minimal supervision
.Key Responsibilitie
sLine DAP, Installation & Commissionin
- gParticipate in Design Approval (DAP) reviews of the assembly line with the equipment supplier, evaluating station-wise design, controls architecture, and utility requirements before finalization
- .Represent maintenance/engineering interests during Factory Acceptance Testing (FAT) at the supplier's site and Site Acceptance Testing (SAT) post line-shifting
- .Lead installation, mechanical/electrical erection, and commissioning of all line stations, ensuring adherence to layout, safety, and utility specifications
- .Own the punch-list closure process with the equipment vendor and drive resolution of any documentation or technical gaps identified during evaluation and FAT
.Process & Equipment Ownershi
- pSet up and validate the maintenance process framework for the line – preventive maintenance (PM) schedules, predictive maintenance practices, spare parts strategy, and breakdown response protocols
- .Define and institutionalize SOPs, checklists, and maintenance KPIs (MTTR, MTBF, OEE contribution) for each station
- .Act as the final technical escalation point for equipment issues across Cell Loading, Module/Pack Assembly, Screwing, Testing, and Container Line stations
.Automation, Controls & ME
- SProvide expert-level support on PLC programming, troubleshooting, and modification (line PLC architecture, I/O, HMI) across all automated stations
- .Manage servo drive systems and motion control, with hands-on expertise in industrial robots – Fanuc, ABB, and Kuka – deployed on the line
- .Own upkeep and troubleshooting of vision camera/inspection systems used for quality checks across stations
- .Own MES (Manufacturing Execution System) integration at the shop floor level – data capture, traceability, downtime logging, and interface with line PLCs/SCADA
- .Work closely with the line supplier's automation team during commissioning to ensure smooth handover and knowledge transfer to the in-house team
.Process Engineering & Desig
- nOwn process engineering design for the assembly line – station-wise cycle time, process flow, and equipment parameter setting to meet quality and output targets
- .Review and validate process design inputs from the line supplier during DAP and translate them into executable, plant-specific process setups
- .Continuously improve process design based on line performance data, driving reduction in cycle time losses and process-related downtime
.Mechanical Maintenanc
- eLead maintenance of mechanical systems including pneumatics, gearboxes, conveyors, indexing/transfer systems, and fixtures/tooling
- .Ensure timely calibration and maintenance of torque/screwing systems, vision systems, and testing equipment
- .Build and manage a spares inventory strategy (critical spares, insurance spares) for mechanical and automation components
.Utilities Managemen
- tOwn sizing, installation, commissioning, and ongoing maintenance of plant utilities including HVAC, air compressors, and associated distribution systems (dry air, chilled water, as applicable)
- .Coordinate utility load planning with plant engineering to align with connected/contracted load requirements for the assembly line
- .Ensure utility uptime and redundancy planning to avoid production disruption
.Safety & Complianc
- eChampion a strong safety culture on the shop floor – LOTO (Lockout-Tagout), machine guarding, electrical safety, and safe work permits for maintenance activities
- .Ensure all maintenance activities comply with statutory, EHS, and factory safety norms; lead incident investigation and corrective action for equipment-related safety events
- .Drive safety training and toolbox talks for the maintenance team and coordinate with the Safety/SHE department on plant-wide initiatives
.Team & Cross-functional Leadershi
- pBuild, train, and lead the maintenance team (electrical, mechanical, automation technicians) through the recruitment and ramp-up phases of the plant
- .Own structured, ongoing training of subordinates – PLC/servo/robot handling, MES usage, mechanical maintenance practices, and safety protocols – to build a self-sufficient team over time
- .Work independently with a high degree of ownership, proactively flagging risks and driving resolution without close supervision
- .Partner closely with Production, Quality, and Plant Engineering teams to support single → two → three-shift ramp-up
.Cost Optimizatio
- nDrive spares cost reduction through better spares planning, indigenization where feasible, vendor negotiation, and repair-vs-replace decisions
- .Drive power/energy cost reduction across the line and utilities through better load management, equipment efficiency improvements, and monitoring of energy-intensive stations
- .Track and report cost-saving initiatives as part of maintenance KPIs to plant leadership
.Required Qualifications & Experienc
- eB.Tech in Electrical or Electronics Engineering
- .Minimum 15 years of maintenance/engineering experience in a manufacturing environment, with exposure to automated assembly lines (battery, BESS, EV, electronics, or similar high-precision manufacturing preferred)
- .Demonstrated experience across the full line lifecycle – DAP, FAT, installation, SAT, and commissioning – not just steady-state maintenance
- .Strong hands-on expertise in PLC (e.g., Siemens/Allen-Bradley/Mitsubishi), servo systems, and industrial robots – Fanuc, ABB, and Kuka
- .Working knowledge of vision camera/inspection systems and MES systems with shop-floor data integration
- .Practical expertise in pneumatics, gearboxes, conveyor systems, and mechanical maintenance of automated equipment
- .Experience in sizing and maintaining industrial utilities – HVAC and air compressor systems
- .Demonstrated ability to design/own process engineering setups and train subordinates to build team capability
- .Cost-conscious mindset with a track record of driving spares cost and power cost reduction initiatives
- .Proven track record of building or leading a plant safety culture
- .Fluency in Hindi and English is mandatory
- .Based in Delhi NCR or willing to relocate; must be able to work independently at the plant location
.Preferred Attribute
- sPrior experience in a lithium-ion battery pack, BESS, or EV component assembly plant
- .Experience working directly with line equipment suppliers/OEMs during vendor evaluation, FAT, and commissioning phases
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