Senior Engineer - Maintenance (Plastics)

Role & responsibilities

Injection Molding Machine Maintenance

• Perform maintenance of hydraulic, electrical, mechanical, and servo-controlled injection molding machines.
• Troubleshoot and rectify machine breakdowns involving hydraulic systems, motors, pumps, valves, sensors, heaters, thermocouples, and control panels.
• Maintain machine clamping units, injection units, screw and barrel assemblies, tie bars, toggle mechanisms, and hydraulic power packs.
• Diagnose faults in PLCs, HMI systems, servo drives, VFDs, temperature controllers, and electrical circuits.
• Coordinate machine installation, commissioning, calibration, and major overhauls.

Preventive and Predictive Maintenance

• Prepare and implement preventive maintenance schedules for injection molding machines and auxiliary equipment.
• Conduct routine inspections, lubrication, tightening, alignment, and replacement of worn-out components.
• Monitor equipment health and identify potential failures through condition-based maintenance.
• Maintain maintenance checklists, equipment history cards, and machine-wise maintenance records.
• Analyze recurring breakdowns and implement permanent corrective actions.

Breakdown Analysis and Continuous Improvement

• Respond promptly to machine breakdowns and minimize production downtime.
• Conduct Root Cause Analysis (RCA) using 5 Why, Fishbone, and other problem-solving techniques.
• Implement corrective and preventive actions to eliminate recurring failures.
• Drive improvements in MTBF, MTTR, machine availability, and maintenance cost.
• Identify opportunities for energy conservation, spare parts optimization, and equipment reliability improvement.