Engineer - Maintenance

Job Title: Engineer -Maintenance
Company & Location: Tata Ficosa Automotive system, Sanand, Gujarat

Job Summary:

TATA FICOSA Automotive Systems Pvt Ltd is currently seeking a seasoned and dynamic Maintenance Engineer to bolster our team at the facility in Gujarat. The ideal candidate should possess extensive experience in the Maintenance department within the automotive industry, with a strong emphasis on expertise in Hydraulics, Pneumatics, PLC, HMI, Drives, TQM, Kaizen, ESG (Environmental, Social, and Governance) initiatives.

Job Description:

1. Hands-on experience in Automation System:

• Programming, Installation, commissioning & troubleshooting of PLC, HMI, (Preferably Delta & siemens Make).
• Expertise in Delta make, PLC, HMI, VFD & servo.
• Installation, commissioning & troubleshooting of VFD, Servo drive. (Delta & siemens make.)
• Knowledge & hands on experience in various types of analogue and digital sensors.
• Experience in different types of communication protocols. Modbus, Ethernet & can open.
• Knowledge & experience in different types of 3rd party devices communication with PLC, HMI printer etc.
• Experience in control, power panel wiring & troubleshooting.
• Knowledge & experience in machine barcode traceability system & LabVIEW.
• Knowledge & experience in different types of LVDT sensor, proximity sensors, photo sensors read switches, limit switches, load cell, Printers Etc.
• Knowledge in Industry 4.O & MES system.
• Software proficiency: Delta PLC Software- WPL Soft, ISP Soft, Delta HMI- DOP Soft, Delta Servo -ASDA- A2 & A3 Series, Siemens PLC-TIA Portal, VFD- Starter Etc.

1. Equipment Up Time Optimization:

• Strategize spare parts inventory for maintenance activities.
• Monitor inspection and maintenance procedures closely.
• Implement corrective actions promptly to ensure maximum machine uptime.
• Quick Attending daily breakdowns and emergencies related to machines & utilities.
• Supervise condition of all equipments & potential upgradation to reduce downtime & repetitive failures
• Data collection & analysis of machine breakdown data.
• Ensuring maximum uptime & minimum downtime of machines.
• Maintain MTTR & MTBF.

1. Preventive and Predictive Maintenance:

• Schedule preventive maintenance tasks for all machinery.
• Allocate necessary resources for maintenance activities.
• Analyse machine data to propose predictive maintenance measures.
• Oversee maintenance operations to minimize machine downtime.
• Ensured preventive & predictive maintenance should be carried out as per plan.
• Maintain all maintenance documents.
• Experience in audit compliance handling process.

1. New Machine Installation:

• Trail, erection& commissioning of new machines.
• Store the updated PLC program backups.
• Maintain Machines manual, electrical, mechanical & pneumatic drawing.
• Correct all required modifications in PLC & HMI from supplier during machine installation process.

1. Spare parts Management:

• Ensuring adequate spare required for machine & equipments.
• Daily tracking of spare stock.
• Ensuring zero maintenance due to spare control.
• Knowledge & experience in PR, PO Process in SAP system.
• Suppliers follow up for on time receiving the spares.

1. Safety System:

• Follow the proper LOTO procedure while working on machines
• Adhere to the safety standards & legal regulations while executive maintenance management task & program.

1. People Management:

• Establish a skill inventory within the maintenance function.
• Delegate responsibilities to junior staff and ensure adherence to processes.
• Coach and mentor junior team members for skill enhancement.
• Conduct training sessions to educate junior staff on functional aspects.

1. SAP Maintenance module

• Knowledge & hands-on experience in SAP maintenance module

1. Continuous Improvement Initiatives:

• Ensure effective implementation of Poka-yoke methods.
• Spearhead projects aimed at cost reduction.
• Explore opportunities for localizing imported machine spares to minimize maintenance costs.
• Energy saving project implementation.
• Implementation of effective kaizens for process improvement & quality improvement.
• Existing machine program modification for reducing minor stoppages & repetitive failures.

Qualifications and Skills:

• Essential: B.E. in Electrical/Electronic Engineering with 4 - 5 years of experience in the Automotive Industry.
• Proven expertise in Hydraulics, Pneumatics, PLC, HMI, Drives, TQM, Kaizen.