Senior Maintenance Engineer

JOB DESCRIPTION SR. MAINTENANCE ENGINEER
Department: Maintenance / Engineering
Position: Maintenance Engineer
Reports To: HOD
Location: Sheet Metal Manufacturing Plant
Industry: Automotive / Engineering / Sheet Metal Components
Key Responsibilities
A. Maintenance Planning & Execution
Develop and implement annual, monthly and daily maintenance plans.
Ensure preventive and predictive maintenance is carried out as per schedule.
¢ Minimize machine breakdowns and production downtime.
¢ Monitor MTTR, machine availability and maintenance efficiency.
¢ Establish effective breakdown-response systems.
¢ Analyze recurring breakdowns and implement permanent corrective actions.
¢ Maintain equipment history and maintenance records.
B. Sheet Metal Machinery Maintenance
Responsible for maintenance of:
¢ Mechanical / hydraulic / pneumatic power presses.
¢ Press brakes and shearing machines.
¢ Spot welding, MIG and other welding equipment.
¢ Robotic welding systems, where applicable.
¢ Compressors, air dryers and pneumatic systems.
¢ Pumps, motors, gearboxes and conveyors.
¢ EOT cranes, hoists and material-handling equipment.
¢ DG sets, electrical panels and distribution systems.
¢ HVAC, cooling systems and other utilities.
¢ Plant electrical, mechanical and utility infrastructure.
C. Electrical & Automation
¢ Ensure preventive maintenance of HT/LT electrical systems.
¢ Monitor electrical panels, MCCs, PCCs, transformers, motors and drives.
¢ Ensure PLC, HMI, sensors, VFD and automation-system reliability.
¢ Coordinate troubleshooting of electrical and automation failures.
¢ Maintain proper electrical safety and statutory compliance.
¢ Monitor power consumption and identify energy-saving opportunities.
D. Preventive & Predictive Maintenance

¢ Prepare equipment-wise preventive-maintenance checklists.
¢ Establish maintenance frequencies based on OEM recommendations and machine
history.
¢ Implement condition monitoring such as vibration, temperature, oil condition and
electrical health checks where applicable.
¢ Ensure timely replacement of wear parts, bearings, seals, belts, chains and other critical
components.
¢ Develop critical-spares and preventive-replacement plans.
E. Breakdown Management
¢ Lead the maintenance team during major breakdowns.
¢ Ensure quick response and restoration of production.
¢ Conduct Root Cause Analysis (RCA) for major and repetitive failures.
¢ Implement CAPA to prevent recurrence.
¢ Track breakdown hours and identify top loss-making machines.
F. Dies, Fixtures & Tooling Support
¢ Coordinate maintenance and repair of production dies, fixtures and tooling.
¢ Ensure timely availability of dies and fixtures for production.
¢ Improve die/fixture life through preventive maintenance.
¢ Coordinate with Tool Room, Production and Quality teams for recurring tooling issues.
G. Spare Parts & Inventory Management
¢ Identify critical machine spares and maintain minimum stock levels.
¢ Control maintenance inventory and avoid unnecessary purchases.
¢ Develop alternate/local sources for critical components.
¢ Review spare consumption and obsolete inventory.
¢ Coordinate with Purchase and Stores for timely procurement.
H. Team Management
¢ Lead, train and develop maintenance engineers, supervisors, electricians, fitters and
technicians.
¢ Allocate manpower according to shift and equipment requirements.
¢ Establish clear responsibilities and escalation procedures.
¢ Conduct skill-gap analysis and technical training.
¢ Ensure discipline and adherence to maintenance procedures.
I. Safety & Compliance
¢ Ensure compliance with plant safety procedures.
¢ Implement LOTO (Lockout/Tagout) practices during maintenance.

¢ Ensure safe working practices for electrical, mechanical, welding and height-related
maintenance activities.
¢ Conduct periodic safety inspections.
¢ Ensure statutory inspections and certifications of applicable equipment such as cranes,
pressure systems and electrical installations.
¢ Investigate maintenance-related accidents and implement corrective actions.
J. Cost Control & Energy Management
¢ Prepare and control the maintenance budget.
¢ Reduce breakdown, spare-parts and repair costs.
¢ Monitor maintenance cost per machine / production unit.
¢ Identify energy-saving opportunities.
¢ Reduce compressed-air leakage, power losses and utility wastage.
¢ Evaluate repair-vs-replacement decisions for major equipment.
K. Continuous Improvement
¢ Implement TPM, 5S, Kaizen and Lean Maintenance practices.
¢ Improve OEE through better machine reliability.
¢ Identify chronic losses and develop improvement projects.
¢ Standardize maintenance procedures and checklists.
¢ Drive automation and condition-monitoring initiatives where economically justified.
L. Documentation & Reporting
Maintain and review:
¢ Preventive-maintenance schedules.
¢ Breakdown reports.
¢ Machine history cards.
¢ MTBF / MTTR reports.
¢ Machine availability reports.
¢ Spare-parts records.
¢ Maintenance cost reports.
¢ RCA and CAPA reports.
¢ Annual maintenance plans and budgets.
¢ Utility consumption reports.
¢ Statutory inspection records.