Maintenance Engineer

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Maintenance Engineer 

PURPOSE OF THE ROLE:

Plant Maintenance Engineer is responsible for ensuring the availability of all manufacturing plants by implementing activities that are safe, timely, cost effective and of required quality.

He/ She is responsible and accountable to ensure activities like Preventive maintenance, breakdown maintenance, predictive maintenance, improvements and shift activities pertaining to plant Machineries are carried out as per schedule and required timeline. He/ She is responsible and accountable for Plant & Personal Safety. He/ She must ensure usage of all necessary PPEs by technicians and contract person while doing any activities where exposure is expected as defined in PTW. He/ She is also responsible and accountable for safe operation and housekeeping activity. He/ She will coordinate and communicate with other dept. He/ She must follow IMS as per requirement. He/ She shall take care of consumables and critical spare inventory at plant level. He/ She will perform ACA of all equipment and FMEA for critical equipment in coordination with Site reliability.

ROLES AND RESPONSIBILITIES:

• Planning & execution of maintenance activities in coordination with R-Manager.
• Implementing & execution of preventive maintenance of Equipment as per planning schedule. Ensure preventive maintenance is carried out as per checklist with proper documents.
• Adding/ deletion of maintenance plan/equipment/function location as per procedure without any deviation.
• Close monitoring and technical completion of Each maintenance Orders on daily basis
• Daily co-ordination with Plant Managers to achieve targeted production. Understanding the issues and taking timely countermeasures.
• Observing and analyzing mechanical equipment using standardized checklists, planting rounds and precision equipment and taking corrective measures.
• To attend breakdown activities in minimum possible timeframe and handover equipment for production.
• To optimize breakdown with proper RCA and CAPA to increase MTBF.
• Participate in Web based training, on job training and workshops.
• Monitor consumption and availability of critical spares, analyze & trouble shoot breakdowns to improve plant safety and uptime.
• Providing proper work permits for their subordinates and Workers of Contract Agencies as per PTW procedure.
• Implementation/updating and monitoring of IMS.
• Prioritization of Jobs in coordination with Production team/MGL/STM.
• Selection/Upgradation of MOC for equipment, piping, Gasket coordination with plant manager /Process engineer/MGL/STM / Site reliability
• To raise Gate pass requisition for external services.
• Vendor selection for material as well as service in coordination with Central Function/ Site reliability.
• Communication to external agencies/Vendors.
• Allocation of Jobs to External Agencies as per ARC scope.
• Follow asset management system by ACRT tool.
• Timely capitalization of Assets.
• Verification of existing assets and updating in SAP.
• SAP updating (Creation/deletion of Functional location, equipment, PM plan and scheduling, Order, Notification, Purchase requisition, Confirmation and Technical confirmation of Order, manpower utilization posting)
• RM cost analysis and Capex budget utilization.
• To prepare monthly maintenance report.
• Prepare Quarterly progress reports and present in Quarterly review meeting.
• Coordination with Engineering Stores/MRP controller for MRO materials and critical sparse.
• To Support Eng store for timely posting of GRN by carrying out Inspection and validation of materials/Equipment received against Purchase Order as per required specification
• Manpower & resource planning for maintenance /improvement project.
• Conduct TBM with plant team every month to discuss bad actors and action items.
• Closely monitoring and implementation of action items of TBM
• Issue Materials from Engineering Stores for maintenance activities and other routine work. Return the Materials to Engineering Stores as per procedure.
• Prepare Shift Schedule of Technicians and uploading in Spine HR tool.
• Follow leave and OT management as per HR guideline.
• To prepare Purchase requisition for material and service in SAP and Smart Buy.
• To raise service entry sheet for contract agencies against invoices after checking of measurement sheet.
• To set objective/goal in Growth Management System for Technician of their respective area.
• To do Performance evaluation of Technician.
• To participate in Audits and timely closing of findings/observation of audits.
• To Conduct/participate in MSA.
• To take necessary action in Intelex for closing of aby abnormalities/observation
• Propose R&M budget, Wish list for NPC and MOC cost estimation.
• Support PCT for installation/removing instruments as and when required.
• Support the Safety department for installation/removing Firefighting equipment.
• Support to electrical department for removing/maintenance/installation/shifting of motors.
• Support to Verify P& ID, plant layout and Equipment drawings.
• Conducting & planning for FAT in coordination with third party vendor for new equipment.
• Support to other production plants in absence of PME.
• Manage Visitor Management system.
• Following ACA and FMEA procedure for their respective plant machinery and implementing the outcome of recommendation in coordination with Site reliability.
• Support OnePSS /OneAPM and asset care as per procedure.
• Ensure standardization of equipment / spares and process is maintained across the site in coordination with team members and site reliability

Legal regulation compliance and Safety

• He/ She Shall understand all applicable local legal regulations including Gujarat factory rules and country factory acts and ensures that they are addressed appropriately.
• Planning & execution of statutory requirements in coordination with production & competent personnel and maintaining documents.
• To Complete various statutory tasks in We Comply tool.
• Ensuring the safety of equipment and people by following PTW and other safety guidelines.
• Participate in plant and process safety study (A3R, A4R & MOC) and timely completion of recommendation and completion of documentation.
• Facilitate effective first aid and emergency measures in case of any abnormal event.
• To Participate in EHS co-ordination meetings.
• Give Intimation about undesired events to concern department, participate in RCA and implementation of CAPA and record in Intelex.

Improvement projects

• • Execution of all improvement projects/NPC at plant level and places with appropriate resources.
  • Ensures Quality of installations are in line with company standards/requirements.
  • To participate in Plant rounds, EHS round, One PSS round, PPS round and comply observations.
  • To Conduct Gemba walk to ensure awareness of one PSS standard best practice.
  • Completion of near-miss, One PSS suggestion points and recommendation of undesired events.
  • Execution of MOC, NPC and Capex activities within timeline, quality and budget.

Contractor management

• • Responsible for planning and allocation of the right contractors for the right job
  • Reviews the completed jobs with the contractor in charge.
  • Conduct Contract Evaluation twice in year to improve quality, safety, billing cycle.

People

• • Be a coach and mentor to the people.
  • Provide timely feedback.
  • Impart technical knowledge and Skill to the technicians through on job training and workshops.
  • Participating and Encouraging subordinates to report near miss & give improvement suggestions.
  • Participating and Encouraging subordinates to participate in various trainings/awareness programs.
  • Identify talents and take ownership to develop them.
  • Safety of people

Key Working Relation:

Internal

• • Production Team - Setting priorities and close collaboration.
  • Other Engineering Departments (PCT, Civil, Electrical, Utility)- Support for execution of maintenance activities.
  • Project Team - Collaborates with the project team for improvement projects.
  • Procurement Team - Procurement of equipment.
  • Head of Safety and Environment - Establishing the safety and sustainability objectives and standards.
  • Head of Site services - Liaising with contractors and authorities, communication with security for visitors and external vendors.
  • Process and Plant safety community - Regular updates on process safety topics.
  • Engineering Store- Coordination with Engineering Stores/MRP controller.
  • HR Department- Co-ordination for attendance, leave and OT management system.

External

• • Construction/maintenance contractors - continuous engagement with all contractors
  • Inspection agencies - Quality inspection agencies who play a vital role in having the right quality standard.
  • Suppliers - Engaging with different suppliers to ensure timely support from them.
  • Industries - Be a part of the industry community and share knowledge.

WHO YOU ARE:

• Mechanical Engineering graduate with hands-on plant maintenance experience.

• Strong in preventive, predictive & breakdown maintenance of mechanical equipment.

• Skilled in SAP-PM, spares management, documentation and reporting.

• Good knowledge of safety systems (PTW, IMS) and statutory compliance.

• Able to coordinate with production, safety, stores, vendors and contractors.

• Safety-focused team player with strong problem-solving and execution skills.

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