Deputy General Manager (DGM), Mechanical

Deputy General Manager (DGM), Mechanical

Role Purpose

Provide leadership and technical direction for all mechanical assets and systems across the refinery (and associated utilities), ensuring plant reliability, availability, integrity, and statutory compliance. The DGM, Mechanical drives strategic maintenance, condition-based/reliability-centered programs, shutdown/turnaround planning, and continuous improvement to support safe, cost‑effective, and sustainable production in line with DSR’s business objectives.

Key Accountabilities

1) Strategy & Governance

• Translate business plans into mechanical asset strategies, policies, standards, and lifecycle plans (design → operate → maintain → upgrade/retire).
• Champion Reliability-Centered Maintenance (RCM), Asset Criticality Ranking, and Root Cause Analysis (RCA) across all mechanical disciplines.
• Establish and enforce Mechanical Integrity and change management (MOC) processes aligned with statutory and OEM requirements.
• Own mechanical sections’ KPIs, dashboards, and governance cadences, drive continuous improvement and cost optimization.

2) Operations & Maintenance Leadership

• Lead planning and execution of preventive, predictive, and corrective maintenance on critical equipment: melting/processing trains, boilers, steam systems, turbines, power transmission, conveyors, crystallizers, centrifugals, vacuum pans, pumps, gearboxes, compressors, utilities (water, air, cooling water systems), and packaging lines.
• Ensure robust maintenance planning & scheduling (weekly, monthly, annual), spares optimization, and work order management through the CMMS.
• Drive Turnaround/Shutdown scope development, critical path scheduling, resource loading, and flawless execution.
• Assure quality of maintenance works, adherence to SOPs, and proper documentation/as-built updates.

3) Reliability & Performance

• Implement condition monitoring (vibration analysis, thermography, oil analysis) and predictive maintenance programs to reduce unplanned downtime.
• Lead RCFA/RCA on chronic failures; institutionalize lessons learned and design-out solutions.
• Optimize equipment performance (OEE, MTBF, MTTR) and energy efficiency; eliminate bottlenecks and chronic losses.
• Benchmark against internal/external best practice; deploy Kaizen/Lean/Six Sigma initiatives where relevant.

4) Projects, Turnarounds & Modifications

• Co-lead mechanical scope in capex projects (brownfield/greenfield), from design reviews (HAZOP/HAZID) to commissioning & start-up.
• Manage retrofits, upgrades, debottlenecking, and fabrication through in-house workshops and vendors, ensuring quality and compliance.
• Ensure MOC, design standards, and asset data integrity are maintained throughout the project lifecycle.

5) HSE & Compliance

• Enforce Zero Harm culture and compliance with OSHA/Factory Acts, pressure vessel/boiler codes, lifting equipment regulations, and OEM standards.
• Conduct/oversee risk assessments (JSA, PTW, Lockout/Tagout, confined space) and ensure timely closure of audit actions.
• Maintain statutory records, certifications, and inspections for mechanical assets.

6) People Leadership & Capability

• Build a high‑performing team: support recruitment, coach, and develop mechanical managers/engineers/technicians; define roles, succession pipelines, and development plans.
• Drive cross-functional collaboration with Operations, Electrical & Instrumentation, Projects, HSE, QA/QC, and Supply Chain.
• Foster a culture of discipline, accountability, data-driven decisions, and continuous learning.

7) Financial & Supply Chain Management

• Own the mechanical OPEX/CAPEX budgets; deliver cost savings without compromising asset integrity or safety.
• Optimize spare parts strategy (critical spares, safety stock,local sourcing), vendor qualifications, and service agreements.
• Validate technical scopes, TCO, and commercial evaluations with Procurement.

Qualifications, Experience & Skills

Education

• B.Eng./B.Sc. in Mechanical Engineering (or related discipline) - required
• M.Eng./MBA — added advantage
• COREN or equivalent professional registration - preferred

Experience

• 12–18+ years post‑qualification experience in heavy process industries (sugar, food & beverage, FMCG, cement, chemicals, petrochemicals, pulp & paper, or power).
• At least 5+ years in senior leadership (multi-section/multi-plant responsibility).
• Proven leadership of turnarounds, RCM/TPM, and reliability programs.

Technical Skills

• Expert knowledge of rotating and static equipment (pumps, gearboxes, conveyors, boilers, pressure vessels, heat exchangers, turbines, crystallizers, centrifugals).
• Proficiency in RCM, RCA, condition monitoring, precision maintenance, alignment/balancing.
• Strong in maintenance planning & scheduling, and spares strategy.
• Working knowledge of HSE systems, PTW/LOTO, and relevant codes/standards.

Leadership & Behavioral Competencies

• Strategic thinking, data‑driven decision making, and strong execution discipline.
• Excellent stakeholder engagement, vendor management, and influencing skills.
• People development, coaching, delegation, and performance management.
• High integrity, resilience, and results orientation.

Certifications (Preferred/Added Advantage)

• Project Management (e.g., PMP/Prince2)
• Vibration Analysis/Condition Monitoring certifications
• Boiler/Pressure Vessel inspection/competency certifications (as applicable)

Working Conditions

• Plant/industrial environment with exposure to noise, heat, rotating/pressurized equipment; use of PPE is mandatory.
• Shift/extended hours during shutdowns/turnarounds and critical interventions.
• Travel: Up to 20–30% between DSR sites.

Role Interfaces

• Internal: Operations/Production, E&I/Automation, Projects/Engineering, HSE, QA/QC, Supply Chain, Finance, HR/L&D.
• External: OEMs, EPCs, service contractors, regulatory/inspection bodies, utilities providers.
• Decision Rights & Authority
• Approve mechanical maintenance plans, shutdown scopes, and resource allocation within delegated limits.
• Technical approval for mechanical specs, workmanship quality, and acceptance of completed works.
• Recommend capex, vendor selection, and major repairs/overhauls to the GM/Plant Director.
• Enforce asset integrity and HSE compliance; stop work authority where safety is compromised.

Deputy General Manager (DGM), Mechanical

Role Purpose

Provide leadership and technical direction for all mechanical assets and systems across the refinery (and associated utilities), ensuring plant reliability, availability, integrity, and statutory compliance. The DGM, Mechanical drives strategic maintenance, condition-based/reliability-centered programs, shutdown/turnaround planning, and continuous improvement to support safe, cost‑effective, and sustainable production in line with DSR’s business objectives.

Key Accountabilities

1) Strategy & Governance

• Translate business plans into mechanical asset strategies, policies, standards, and lifecycle plans (design → operate → maintain → upgrade/retire).
• Champion Reliability-Centered Maintenance (RCM), Asset Criticality Ranking, and Root Cause Analysis (RCA) across all mechanical disciplines.
• Establish and enforce Mechanical Integrity and change management (MOC) processes aligned with statutory and OEM requirements.
• Own mechanical sections’ KPIs, dashboards, and governance cadences, drive continuous improvement and cost optimization.

2) Operations & Maintenance Leadership

• Lead planning and execution of preventive, predictive, and corrective maintenance on critical equipment: melting/processing trains, boilers, steam systems, turbines, power transmission, conveyors, crystallizers, centrifugals, vacuum pans, pumps, gearboxes, compressors, utilities (water, air, cooling water systems), and packaging lines.
• Ensure robust maintenance planning & scheduling (weekly, monthly, annual), spares optimization, and work order management through the CMMS.
• Drive Turnaround/Shutdown scope development, critical path scheduling, resource loading, and flawless execution.
• Assure quality of maintenance works, adherence to SOPs, and proper documentation/as-built updates.

3) Reliability & Performance

• Implement condition monitoring (vibration analysis, thermography, oil analysis) and predictive maintenance programs to reduce unplanned downtime.
• Lead RCFA/RCA on chronic failures; institutionalize lessons learned and design-out solutions.
• Optimize equipment performance (OEE, MTBF, MTTR) and energy efficiency; eliminate bottlenecks and chronic losses.
• Benchmark against internal/external best practice; deploy Kaizen/Lean/Six Sigma initiatives where relevant.

4) Projects, Turnarounds & Modifications

• Co-lead mechanical scope in capex projects (brownfield/greenfield), from design reviews (HAZOP/HAZID) to commissioning & start-up.
• Manage retrofits, upgrades, debottlenecking, and fabrication through in-house workshops and vendors, ensuring quality and compliance.
• Ensure MOC, design standards, and asset data integrity are maintained throughout the project lifecycle.

5) HSE & Compliance

• Enforce Zero Harm culture and compliance with OSHA/Factory Acts, pressure vessel/boiler codes, lifting equipment regulations, and OEM standards.
• Conduct/oversee risk assessments (JSA, PTW, Lockout/Tagout, confined space) and ensure timely closure of audit actions.
• Maintain statutory records, certifications, and inspections for mechanical assets.

6) People Leadership & Capability

• Build a high‑performing team: support recruitment, coach, and develop mechanical managers/engineers/technicians; define roles, succession pipelines, and development plans.
• Drive cross-functional collaboration with Operations, Electrical & Instrumentation, Projects, HSE, QA/QC, and Supply Chain.
• Foster a culture of discipline, accountability, data-driven decisions, and continuous learning.

7) Financial & Supply Chain Management

• Own the mechanical OPEX/CAPEX budgets; deliver cost savings without compromising asset integrity or safety.
• Optimize spare parts strategy (critical spares, safety stock,local sourcing), vendor qualifications, and service agreements.
• Validate technical scopes, TCO, and commercial evaluations with Procurement.

Qualifications, Experience & Skills

Education

• B.Eng./B.Sc. in Mechanical Engineering (or related discipline) - required
• M.Eng./MBA — added advantage
• COREN or equivalent professional registration - preferred

Experience

• 12–18+ years post‑qualification experience in heavy process industries (sugar, food & beverage, FMCG, cement, chemicals, petrochemicals, pulp & paper, or power).
• At least 5+ years in senior leadership (multi-section/multi-plant responsibility).
• Proven leadership of turnarounds, RCM/TPM, and reliability programs.

Technical Skills

• Expert knowledge of rotating and static equipment (pumps, gearboxes, conveyors, boilers, pressure vessels, heat exchangers, turbines, crystallizers, centrifugals).
• Proficiency in RCM, RCA, condition monitoring, precision maintenance, alignment/balancing.
• Strong in maintenance planning & scheduling, and spares strategy.
• Working knowledge of HSE systems, PTW/LOTO, and relevant codes/standards.

Leadership & Behavioral Competencies

• Strategic thinking, data‑driven decision making, and strong execution discipline.
• Excellent stakeholder engagement, vendor management, and influencing skills.
• People development, coaching, delegation, and performance management.
• High integrity, resilience, and results orientation.

Certifications (Preferred/Added Advantage)

• Project Management (e.g., PMP/Prince2)
• Vibration Analysis/Condition Monitoring certifications
• Boiler/Pressure Vessel inspection/competency certifications (as applicable)

Working Conditions

• Plant/industrial environment with exposure to noise, heat, rotating/pressurized equipment; use of PPE is mandatory.
• Shift/extended hours during shutdowns/turnarounds and critical interventions.
• Travel: Up to 20–30% between DSR sites.

Role Interfaces

• Internal: Operations/Production, E&I/Automation, Projects/Engineering, HSE, QA/QC, Supply Chain, Finance, HR/L&D.
• External: OEMs, EPCs, service contractors, regulatory/inspection bodies, utilities providers.
• Decision Rights & Authority
• Approve mechanical maintenance plans, shutdown scopes, and resource allocation within delegated limits.
• Technical approval for mechanical specs, workmanship quality, and acceptance of completed works.
• Recommend capex, vendor selection, and major repairs/overhauls to the GM/Plant Director.
• Enforce asset integrity and HSE compliance; stop work authority where safety is compromised.