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Head – Plant Engineering, Maintenance & Automation Role Overview The role is responsible for end-to-end leadership of plant engineering, utilities, maintenance, and automation for large-scale, highly automated manufacturing facilities. This position drives plant setup, operational excellence, cost optimization, equipment reliability, digital factory initiatives, and safety compliance across manufacturing operations such as BESS, EV, and automotive plants.
The role requires strong cross-functional leadership, deep technical expertise in utilities and automation, and a strategic mindset to scale operations from project phase to stable, high-performance manufacturing.
Key ResponsibilitiesPlant Engineering & Infrastructure
- Lead greenfield and brownfield plant setup, including utilities, infrastructure, and automation systems.
- Ensure readiness of critical utilities such as power distribution (HT/LT), HVAC, compressed air, cooling systems, water treatment, and BMS.
- Drive statutory compliance, approvals, and EHS adherence for all plant infrastructure.
- Support smooth transition from project execution to steady-state plant operations.
Automation & Smart Factory
- Define and execute automation strategy for manufacturing lines, logistics, and utilities.
- Lead deployment of AGVs, ASRS, MES-integrated systems, IoT solutions, and smart factory initiatives.
- Oversee controls integration and equipment selection aligned with process, capacity, and scalability requirements.
- Improve productivity, traceability, and energy efficiency through digital and data-driven systems.
Maintenance & Reliability Engineering
- Develop and execute preventive, predictive, and condition-based maintenance strategies.
- Improve equipment reliability, uptime, MTBF, and MTTR across highly automated lines.
- Reduce unplanned downtime through structured RCA, TPM, and reliability improvement programs.
- Build in-house technical expertise to reduce OEM dependency.
Operations Excellence & Continuous Improvement
- Drive continuous improvement initiatives using 5S, Kaizen, TPM, PDCA, DMAIC, 5M, and Gemba.
- Optimize cycle time, throughput, energy usage, and asset utilization.
- Standardize equipment, spares, and operating procedures to reduce variability and cost.
- Eliminate non-value-added activities and improve overall equipment effectiveness (OEE).
Cost, Budget & Vendor Management
- Own CapEx and OpEx budgets for plant engineering, utilities, and maintenance.
- Deliver cost savings through energy optimization, standardized procurement, and asset lifecycle management.
- Lead vendor strategy including OEMs, EPCs, and IFM partners.
- Manage contracts, SLAs, risk mitigation, and business continuity plans.
People & Stakeholder Leadership
- Lead and mentor large, multi-disciplinary engineering and operations teams.
- Drive cross-functional collaboration across engineering, operations, quality, safety, IT, and supply chain.
- Develop internal SMEs and succession plans.
- Communicate effectively with senior leadership and external stakeholders.
Required Qualifications
Education
- B.Tech / BE in Mechanical Engineering (mandatory)
- Additional certifications in QMS, EHS, or automation preferred
Experience
- 15+ yearsof experience in:
- Plant engineering and utilities
- Maintenance & reliability engineering
- Automation and smart factories
- Large-scale manufacturing operations (BESS / EV / Automobile / Heavy Industry)
- Proven experience in greenfield plant setup, highly automated lines, and utility management.
- Strong leadership experience managing large teams and multi-site operations.
Key Skills & Competencies
- Plant Engineering & Utilities Management
- Automation, Controls & Smart Factory Systems
- BESS & EV Manufacturing Operations
- Maintenance Strategy & Reliability Engineering
- CapEx & OpEx Budgeting
- Vendor & Contract Management
- Energy & Cost Optimization
- EHS & Statutory Compliance
- Data-driven Decision Making
- Strong People Leadership & Change Management
Preferred Experience
- Battery Energy Storage Systems (BESS) manufacturing
- EV or Automotive manufacturing plants
- MES-integrated automation environments
- Large-scale, high-throughput industrial facilities