Senior Engineer – Mechanical Maintenance

 Sr. Engineer – Mechanical Maintenance

 Purpose: Maintain all zones such as Ball mills, KILN, conveyors, vacuum systems, Stirrers, Agitators, Dust collection system, Bowers, spraying system, RO plant, ETP, STP, FIRE HYDRANT & fighting installations, material, handling & lifting equipment like – Fork lifter, HOPT,EOT crane, JIB crane, Electric hoist, chain blocks, Automobiles, ZLD, Chiller, Cooling Tower, Heat Exchangers, dryers, refrigeration system, Industrial gas storage & pumping system (LPG & PNG), compressed air & AIR COMPRESSOR’s Position may also serve as back up for plant equipment.

Qualification: BE/B. Tech – Mechanical with AutoCAD proficiency (AutoCAD, SolidWorks)

Experience: Required Minimum 5-8 years specific on hand work experience- advantage if the experience in same business line/continuous process industry like – Sanitaryware/ceramic field/FMCG/Automobile/Cement/Oil & Gas/Steel/Paper.

 General Requirements:

• Shall be responsible for two primary functions: Equipment Maintenance and co-ordination of TPM system.
• Perform maintenance management by supervising maintenance personnel and establishing priorities in maintenance schedules. Taking decision for Predictive & corrective maintenance of plant equipment based on performance. Control of shift maintenance losses as per plan and deputing manpower for optimum utilization.
• Maintain approvals and assets, utilities, facility, parts inventory, monitoring purchase orders, invoice approvals, and manage the department budget.
• Manage maintenance personnel by setting direction & priorities and provide training & continuous development on all maintenance personnel.
• Ensure the facilities, utilities, layout, and machinery run to their maximum efficiency & output. Manage to upkeep of all the manufacturing assets, resources and assisting in the design & installation of new systems and implementation of energy saving projects.
• Timely Perform Performance Evaluations on direct reports and Verify Performance Evaluations are being performed on technical work force.
• Drive the Maintenance & Reliability initiative focused on Preventive & Predictive Maintenance, not reactive and maintain work order & inventory management.
• Managing, maintaining, and establishing maintenance procedures to ensure production meets & performs better than budget.
• Developing and maintaining quality & safety standards. Develop associate and supervisor skills by conducting training meetings, one on one development sessions, outside technical skills training, establishing, and monitoring performance reviews for supervisors.
• Setting and maintaining departmental budget by reviewing financial statements, monitoring efficiencies & cost and other expenses.
• Participate in designing & developing future production capacities & improvements by coordinating with user departments and updating maintenance operating procedures & schedules to incorporate the changes.
• Design & maintain mechanical maintenance plans, strategies, Schedules, procedures & methods for the plant & critical utility equipment’s.
• Ability to maintain water records such as RO water, RAW water, ETP, ZLD, Fire Hydrant & STP Waters as per the statutory & legal requirements. All fire prevention equipment was maintained and tested to insure 100% operation.
• Need to have knowledge on statutory & legal requirements for utility services and Maintain Daily logbooks & records accordingly.
• Adherence of preventive maintenance schedule. Carry out routine maintenance work and respond to equipment faults and diagnose breakdown problems.
• Monitor and control maintenance costs. Need to work on specific consumption & utilization.
• Ability to operate & update data in SAP, MS word, MS excel, MS power point, AutoCAD & SolidWorks etc and understand & develop drawings in AutoCAD & SolidWorks.
• Design and specify new equipment installations undertaken by the business unit. Prepare project cost estimates and capital appropriation requests justifying proposed spending with economic returns meeting company standards.
• Coordinate with production, maintenance, purchasing departments while preforming engineering activities.
• Must be able to work a flexible schedule & calculate the MTTR & MTBF. Complete engineering projects on time and at or under budget.
• Provide process engineering and troubleshooting support to production, utilities as necessary to meet all the production commitments. Contributes to production flow by minimizing downtime due to equipment/parts failures.
• Willingness to work in a team-based environment and a commitment to continuous learning and improvement. Need to have knowledge on TBT, KAIZEN, HAICHIBAN, 5S, Critical Six, OHSAS, ISO, QMS, EMS and Behaviour Based Safety.

 Typical Responsibilities:

• O& M of RO plant, ETP, STP, ZLD, FIRE HYDRANT SYSTEM & AIR COMPRESSOR simultaneously.
• Maintain required inventories such as consumables, machinery spares, etc., safe work environment by following company safety procedures, water parameters as per APPCB Standards, AMC for all the required utility machinery, zero leakages in Compressed Air Line & Water Lines and monthly PPT’S Such as graphical representations & improvements.
• Manage the utility maintenance staff and external contractors for the projects & required modifications.
• Worked individually and in teams, demanding & maintaining 0% damage & injury rates.
• Assisting the HOD in mechanical maintenance services of the process machinery, equipment’s & supporting utilities.
• Handling contract management for the plant maintenance and other related activities. PM/CBM Compliance to 100% RCA to be carried out for major & repetitive failures with appropriate corrective action and preventive actions and smooth execution/supervision of ongoing projects and plant modification activities within stipulated time frame with focus on safety and quality.
• Record and analyse non-conformities, initiate corrective action/guide on implementation of corrective/preventive action & MIS. Maintain the QMS & OHSAS system and the subsequent records regarding the plant. Guide and develop the department team members.