DESIGNATION/ TITLE
Senior Maintenance Engineer – ECS, RE
LOCATION
Bengaluru
OBJECTIVE/MISSION
To ensure maximum availability, reliability, efficiency, and safe operation of assembly Special Purpose Machines (SPMs), production machinery, quality testing equipment, plant utilities, warehouse equipment, and infrastructure through effective preventive, predictive, corrective, and continuous improvement maintenance practices while ensuring compliance with EHS and ESG requirements.
KEY RESPONSIBILITIES
Roles and Responsibilities:
The job encompasses but is not limited to the following Roles and Responsibilities:
1. Production Machinery & SPM
- Maintain and troubleshoot automated assembly lines, Special Purpose Machines (SPMs), conveyors, bowl feeders, pneumatic and hydraulic systems, sensors, and actuators.
- Diagnose and resolve issues related to PLCs, HMIs, VFDs, servo drives, motion-control systems, and electrical control panels.
- Support machine installation, commissioning, validation, upgrades, automation improvements, and new projects.
- Ensure optimum machine performance, efficiency, and reliability to support production targets.
2. Quality Testing Equipment Maintenance
- Ensure reliability, calibration, preventive maintenance, and operational readiness of quality testing and laboratory equipment.
- Troubleshoot electrical, electronic, mechanical, and software-related issues in testing equipment.
- Coordinate calibration, certification, validation, and annual maintenance activities.
Equipment Coverage:
- Universal Testing Machine (UTM)
- High Voltage Tester (HV Tester)
- Dielectric Strength Testing Machine
- Insulation Resistance Tester
- Leakage Current Testing Equipment
- Torque Testing Equipment
- Tensile & Compression Testing Machines
- Measuring & Inspection Instruments
- Quality Lab Equipment and Fixtures
3. Utilities & Plant Infrastructure
- Manage maintenance of plant utilities, including:
- Air Compressors
- DG Set (Diesel Generator)
- UPS Systems
- Air Conditioning (AC) Systems
- Stabilizers
- Electrical Distribution Panels
- Lighting & Facility Infrastructure
- Monitor utility performance, energy consumption, and operational efficiency.
- Coordinate statutory inspections, testing, and preventive maintenance of utility systems.
4. Preventive & Predictive Maintenance
- Develop and implement preventive maintenance schedules based on equipment criticality.
- Ensure timely execution and compliance of preventive maintenance activities.
- Maintain equipment history records and maintenance documentation.
- Implement predictive maintenance techniques and condition-monitoring practices to minimize unplanned downtime.
5. Breakdown Management
- Lead troubleshooting activities and ensure rapid restoration of equipment during breakdowns.
- Conduct Root Cause Analysis (RCA), 5-Why Analysis, and corrective action implementation for recurring failures.
- Drive continuous improvements in:
- MTBF (Mean Time Between Failures)
- MTTR (Mean Time To Repair)
- Equipment Availability
- Machine Uptime
- Overall Equipment Effectiveness (OEE)
- Minimize breakdown frequency and production interruptions.
6. Maintenance Planning & Spare Parts Management
- Identify and maintain critical spare parts inventory.
- Coordinate with OEMs, vendors, and AMC/service providers for technical support and maintenance activities.
- Optimize maintenance costs through effective repair-versus-replacement decisions.
- Ensure availability of critical consumables and spare parts to support uninterrupted operations.
7. People Management
- Supervise and guide production technicians.
- Manage external contractors, service providers, and specialized maintenance agencies.
- Build team competency through technical coaching and skill development initiatives.
8. EHS (Environment, Health & Safety) Management
- Ensure compliance with all applicable environmental, health, safety, and statutory requirements.
- Implement and enforce:
- Lockout/Tagout (LOTO)
- Permit-to-Work Systems
- Electrical Safety Practices
- Machine Safety Standards
- Risk Assessment Procedures
- Conduct workplace safety inspections and hazard identification activities.
- Support incident investigations, corrective actions, and preventive actions.
- Ensure preventive maintenance and readiness of firefighting and emergency response systems.
- Drive a zero-accident and zero-unsafe-condition culture within the facility.
9. Safety, Compliance & Documentation
- Maintain maintenance records and asset history documentation.
- Ensure compliance with electrical, mechanical, machine, and workplace safety standards.
- Support internal audits, customer audits, statutory inspections, ISO audits, and compliance requirements.
- Ensure documentation is maintained accurately and updated regularly.
10. Warehouse Equipment Maintenance
- Ensure operational readiness and maintenance of:
- Forklifts
- Stackers
- Material Handling Equipment (MHE),
- Warehouse Utility Systems
- Coordinate periodic inspections, certifications, and statutory compliance requirements.
YEARS OF EXPERIENCE/AGE
7-10 years of relevant experience in manufacturing industries with automated production systems.
QUALIFICATION
Diploma / B.E. / B.Tech in: Electrical Engineering, Mechanical Engineering, Mechatronics, Electronics & Instrumentation, Automation Engineering
Strong Exposure To
Automated Assembly Lines, Special Purpose Machines (SPMs), PLC & Industrial Automation, Pneumatic & Hydraulic Systems, Electrical Power Distribution, Plant Utilities, Quality Testing Equipment
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