Maintenance Engineer

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Key Responsibilities

1. Breakdown Maintenance

• Attend machine breakdowns and troubleshoot equipment failures.
• Conduct Root Cause Analysis (RCA) using Why-Why Analysis techniques.
• Identify defects and abnormalities and implement corrective actions.
• Restore equipment to operational condition within minimum downtime.
• Deploy corrective actions across similar machines to prevent recurrence.
• Coordinate with production and service engineers for machine restoration and improvement activities.
• Participate in daily maintenance review meetings and report maintenance issues.
• Support machine installation, shifting, and NPD-related maintenance activities.

2. Preventive & Predictive Maintenance

• Execute preventive maintenance activities as per the annual maintenance plan.
• Analyze equipment history before conducting preventive maintenance.
• Perform routine inspection of machines and equipment as per maintenance checklists.
• Carry out condition-based maintenance and equipment monitoring.
• Maintain and update TBM (Time-Based Maintenance) schedules and calendars.
• Inspect equipment and spare parts periodically and assess their condition and shelf life.
• Prepare predictive maintenance reports and records.
• Conduct periodic overhauls and preventive maintenance to minimize future breakdowns.

3. Spare Parts & Inventory Management

• Identify critical and non-critical spare parts.
• Ensure machine-wise spare parts availability as per maintenance requirements.
• Generate purchase requisitions (PR) for spare procurement.
• Coordinate with procurement and stores teams for timely availability of spares.
• Optimize inventory levels and reduce inventory carrying costs.
• Standardize common spare parts across equipment where feasible.

4. Cost Reduction & Continuous Improvement

• Implement cost-saving initiatives related to maintenance operations.
• Execute energy-saving projects to improve operational efficiency.
• Identify low-cost, high-life spare parts and maintenance solutions.
• Support Kaizen and continuous improvement initiatives.
• Reduce external service costs through skill development and in-house capability building.

5. Documentation & Compliance

• Update daily breakdown reports in SAP.
• Maintain machine history cards, preventive maintenance records, and predictive maintenance documentation.
• Ensure compliance with IATF, TS, and other quality management system requirements.
• Maintain 5S audit documents and reports.
• Prepare maintenance reports and performance metrics.
• Conduct training for apprentices, operators, and contract workers.

Required Skills & Competencies

• Preventive, Predictive, and Breakdown Maintenance
• Root Cause Analysis (RCA) & Why-Why Analysis
• TBM (Time-Based Maintenance)
• Condition-Based Maintenance (CBM)
• SAP PM Module
• Industrial Troubleshooting
• Spare Parts Management
• Inventory Control
• Kaizen & Continuous Improvement
• 5S and Lean Manufacturing
• IATF / TS Audit Compliance
• Cost Reduction & Energy Management

Preferred Qualification

• B.E./B.Tech/Diploma in Mechanical, Electrical, Mechatronics, or related Engineering discipline.
• Experience in automotive or manufacturing plant maintenance.
• Strong knowledge of industrial machines, equipment maintenance, and reliability engineering