Am / Mgr (Pm M/C Shop Mcd) Waluj

Job Profile :

Level : L3

Designation    : AM / MGR (PLANNED MAINT M/C SHOP MCD) Electronics

Age : Around 27 years

Experience      : Between 3 to 6 years, preferably in Automobile / Engineering Industry

Location : Bajaj Auto Ltd, Waluj – Aurangabad (Maharashtra) – Motorcycle plant

Brief job Description:

Breakdown Maintenance:

1. To Achieve & Sustain Zero breakdown & minor stoppages in Machine shop equipment's like CNC, HMC, VMC, SPMS, honing, PLC automations, pick & place robots, LCA automations.
2. Guide and support team members for quick restoration of daily equipment failures. Do kaizens for reducing MTTR.
3. Analysis of each failure using tools like why-why analysis, root cause failure analysis, Fault tree analysis, FMEA and take immediate restoration actions & countermeasure corrective action to Increase MTBF.
4. Execute various AMCs for Maintenance and servicing of precision equipment's like CMM, tool presters, etc. Co-ordinate with Vendors & central team for systematic execution.
5. Planning & implementation of activities for Zero failures in Electronics systems like- FANUC servo drives, siemens LT modules, 24V SMPS, Various CNC control PCBs, etc.

Preventive Maintenance:

1. To Carryout planned maintenance activities as per yearly/monthly/daily planning of various equipment's like CNC machines, HMC, VMC, Honing, SCARA, PLC automations, Hydraulic & pneumatic Press machines, washing machines, ARPs etc.
2. To Improve & sustain Preventive Maintenance system of Machine shop by doing various kaizens related to MTBPM (part life enhancement) & MTTPM.
3. Regularly revisit & update documents in PM plan, shop equipment's, PM check sheets, etc.
4. Daily/Weekly review of PM system through PM board for sustenance & improvement.

Predictive maintenance:

1. To carry out CBM activities as per plan. Develop new CBM tools & techniques to enhance the CBM efficiency. do kaizens based on CBM data monitoring & analysis.

Budget & Spares Planning & procurement:

1. Planning of fixed cost & spares budget for machine shop
2. Planning of Spares required for general consumables, RBM, CBM, TBM & Insurance spares & regular procurement as per requirement.

Systems & updates:

1. Daily use of CMMS system for PM system compliance: 1. Breakdown entry & Why-why analysis 2. PM compliance 3. Equipment masters 4. PM plan 5. Inventory management, etc.
2. Use of SAP system for Procurement of spares & Spares management.
3. MP information system (Maintenance prevention)

Implementation of activities:

1. Corrective maintenance (CM), Reliability centered Maintenance (RCM), Life cycle cost analysis (LCCA) Artificial intelligence (AI), Online machine health monitoring Systems.
2. Initiate upgradation, reconditioning and modifications in machine.

Improvement activities based on:

1. happened BD cases 2. in-process defects 3. internal customer complaints 4. Safety requirements 5. Quality requirements- error proofing.

1. Maintenance cost saving through alternate source, inhouse development, import substitutes, etc.
2. Energy – Daily Shop energy monitoring & plan for energy consumption reduction through new initiatives, technological upgradations, etc.

Adapt to new technology & trends –

Plan for adaption of new technology changes in Industry 4.0 & IOT, smart manufacturing, automatons, AI, Vision technology, etc.

Guide team members on daily issues and get the work done from them more effectively.

Effective communication with the people down the level and people at higher level.

Exposure / Experience in the following area:

1. Should have experience of working on various CNC machines like Mazak, NTC, FRD, AMS, Brother, Gehring & SPMs like Hydraulic & Pneumatic press, Washing machines, boring machines, Vision systems, CMM machines, Laser marking machines.

1. Should have good knowledge of PMC programming & Maintenance of 

1. FANUC   CNC controllers - Oi,16i,18i,31i MA
2. SIEMENS   CNC controllers – 810D,840D, 840DSL
3. Robot controllers – ABB Pick & place, Fanuc, Mitsubishi SCARA

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2. Should have good knowledge

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2. PLC programming & Maintenance of PLC controllers: Mitsubishi FX /Q series, Siemens S7-300, Siemens VIPA.
3. Servo drives: FANUC, Siemens, ABB, Mitsubishi
4. VFD systems: Mitsubishi, Danfoss, siemens, ABB.

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2. Should be able to upload / download SRAM Backup, Programs, Parameters, Ladder from CNC & PLCs.
3. Should be able to work on PC based systems with HDDs.
4. Should have exposure in Mechatronics – knows basics of sensors, actuators, pneumatics, hydraulics used in Mechanical systems, calibration of systems.
5. Experience on machine PLC logic development independently.
6. Experience on executing AMC of critical machine maintenance & calibration.
7. Should have knowledge and exposure in implementation of TPM systems in Machine shop, including JH activities, PM activities - TBM / CBM, MTTR/MTBF etc.

And knows about kaizen, Pokayoke, Karakuri, 5S, etc.

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2. In-depth knowledge about PM concepts like Why-Why analysis, root cause analysis, fault tree analysis, FMEA, implementation of corrective actions on various equipment.
3. Experience on Planning & execution of PM activities as per plan.
4. Upkeep of Maintenance information: Machine backup data, drawing, Modifications, Manuals, BD history, Countermeasures taken, analysis done etc.
5. Knowledge of SAP systems for procurement of spares & inventory management.
6. Knowledge about latest technological changes in industry – IoT, AI, Smart manufacturing.
7. Experience of working on projects related to IIoT & Cloud integration & new sensors.

Exposure of TPM systems/pillars and basic knowledge of Mechanical Maintenance of Machine shop would be an added advantage.