Assistant Manager-Electrical Machine Maintenance/Controls Maintenance

Sona BLW Precision Forgings Limited
Job Description
JD Code MTE05Department Maintenance Designation AM/DMReports to DGM MaintenanceQualification BE (EEE / ECE / E&I)Preferred industry Automotive Industries / EngineeringExperience 9 - 12 yearsLocation Chennai - MMN
JOB DESCRIPTION
Key Accountabilities / Responsibilities:

• Performance tester design and development using NI hardware and LabVIEW software, including project management, programming, system design, and hardware integration.
• Proficient in handling NI data acquisition systems, including cRIO, cDAQ, PXI, PCI, and USB DAQ .
• Skilled in troubleshooting CNC machines with Fanuc (0i-TF/0i-TD Series), Siemens (840D/828D Series) and Brother controllers.
• Experience with SMT and PCBA machine controls will be an added advantage.
• Hands-on experience with Allen-Bradley (ControlLogix, CompactLogix, SLC, and MicroLogix Series), Siemens (S7-300, S7-1200, and S7-1500), Mitsubishi (FX and Q Series), and Omron (NX and NJ Series) PLCs.
• Strong programming knowledge of Siemens SIMATIC Manager, Siemens TIA Portal, Rockwell RS Logix 5000 and RS Logix 500, Mitsubishi GX Developer, Omron Sysmac Studio, and Pro-face GP-Pro.
• Strong troubleshooting and programming skills in industrial robots, including Epson, Nachi, Mitsubishi, and ABB.
• Hands-on experience with electric nut runners (Desoutter, Bosch Rexroth, and DDK Daiichi), decal printers, PID controllers, and related industrial equipment.
• Application knowledge of the latest control devices, Vision systems (Keyence / Cognex), Various types of sensors, and servo systems, with the ability to select suitable devices and integrate them into existing machines.
• Knowledge of computer hardware and hard disk cloning software.
• In-depth knowledge of VFDs and servo drives, along with PCB troubleshooting expertise.
• Maintenance experience with presses, indexing tables, conveyors and ovens.
• Strong knowledge in electrical and electronics engineering, with the ability to analyse failed control spares and implement effective corrective actions.
• Strong team player with the ability to lead and mentor teams of engineers and technicians.
• Ability to work effectively both independently and within a team environment.
• Exposure to 5S methodologies and Why-Why analysis for root cause identification and problem-solving.
• Awareness of industrial safety standards and practices.
• Basic knowledge of pneumatic and hydraulic systems.

Key Performance Indicators:

• Plan, coordinate, and supervise the day-to-day activities of Controls Engineers and Technicians.
• Review, schedule, and monitor planned and corrective maintenance activities related to machine control systems.
• Lead and manage machine upgrade and modernization projects.
• Analyse machine breakdowns, identify root causes, and implement effective corrective actions and kaizen initiatives.
• Prepare and present departmental performance metrics for monthly management reviews.
• Coordinate with suppliers for sourcing OEM and equivalent machine spare parts.
• Collaborate with internal stakeholders, including Manufacturing, Quality, and Safety departments, to resolve machine-related issues.
• Design and implement process improvements, Poka-Yoke and automation enhancements.
• Drive spare parts cost-reduction and optimization initiatives.
• Coordinate in-house and external repair/service activities for failed machine control cards.
• Identify and implement improvement opportunities to increase the machine;s MTBF / MTTR.
• Manage spare parts inventory, stock levels, and overall inventory control.

Form NumberHR-FR-23Revision Number01OriginatorHRRevision Date27- Mar23