Synopsis of the Role/JD of the role:
- Preventive maintenance of Injection molding machine, high vacuum metallizing machine, Hard coat line, anti fogg machine, assembly line SPM, vibration welding machine, ultrasonic welding machine. Utility like DG set, compressor water chiller etc.
- Verifying equipment inspection check sheets to identify abnormalities and taking the necessary action to overcome on that abnormalities
- MTBF (Mean Time Between Failure) & MTTR (Mean Time to Repair) analysis and taking counter measure
- Breakdown maintenance of Injection molding machine, high vacuum metallizing machine, Hard coat line, anti fogg machine, assembly line SPM, vibration welding machine, ultrasonic welding machine. Utility like DG set, compressor water chiller etc.
- Monthly review of break down report to understand the occurrence & root cause for reducing MTTR & increasing MTBF.
- Preparing counter measure to prevent occurrence of the same problem/abnormality & Horizontally deployment of the same.
- Identifying critical and non-critical spare parts & time to time updating the spare part list as per requirement.
- Upgrading absolute machines though modification of electronic systems and mechanical system upgradation.
- Modification of the machine for improving MTTR & MTBF through analysis of happened breakdowns and week design identification.
1. Maintenance planning and monitoring
Conduct planning for regular, preventive and reactive maintenance activities for utility machines, plant vehicles, tool maintenance, plant facilities and buildings as per the BU maintenance team
Plant Head Plant Maintenance Head Maintenance Lead (3)
Perform manpower planning for the maintenance function at the plant level and allocate work within the team as per employee specialization and experience
Facilitate maintenance for machine software and programs with ensured backlog of 3 years
Track and analyze key maintenance parameters such as mean time failure, depreciation cost, asset utilization, maintenance cost, compliance to machine operating parameters, etc. and feed it as input to BU Maintenance team for further planning
Oversee new machine installation inclusive of commissioning, installation and handover to shop floor workers
2. Cost reduction
Monitor expenditure on maintenance activities across the plant ensuring adherence to allocated budget
Identify and execute cost saving measures and projects in order to reduce maintenance cost and reduce capex, inclusive of preventive maintenance for old-age machines, planning and development of machines in house, standardization of machines, maintaining low spare part inventory and managing procurement of non-BOM items
Conduct root cause analysis and contingency planning to prevent repeated breakdown of parts, machines
3. Energy management
Lead the utility team to carefully monitor energy consumption and track trends on a regular basis
Monitor the energy load to ensure it stays within the sanctions provided by the electricity board. Procure additional
sanctions for increased electricity loads
4. Audits, Controls and Compliance
Plan and manage plant audits in addition to everyday QA checks, including corporate audit for asset verification as
per age and cost of machines, Poka Yoke, TPM, ISO/TS and OSHA audits
Facilitate machine and equipment audits required by customers and submit reports to concerned stakeholders
Manage compliances and utilization of MEP technologies, including MIDC for water, MACB for electricity, effluent treatment plant maintenance etc.
Track and ensure adherence to maintenance controls against sales and ensure standardization of inventory controls
5. New Product Development and Digital Initiatives
Participate in cross-functional team responsible for design and approval process of new product development and line shifts
Assess and plan for integration of new product development through in-house development of new machines, existing machine upgradation or modification as per customer requirements for new parts, products
Support Manufacturing Excellence (ME) teams through IoT to identify minor stoppages and suggest enhancements and improvements of new machines
6. Team development
Carry out performance appraisal of direct reports and identify team members training needs and areas of
improvement
Ensure maintenance staff is adequately trained, equipped and motivated so that the maintenance work can be
completed in a safe, timely and cost-effective manner
Conduct training sessions for shop floor operators and supervisors on correct methods of operations and usage of machine and equipment
