Breakdown Management

Position Name

Department

Functional Area

Qualification:

Years of Experience:

Location:

Purpose of the Position:

• This position is responsible to lead the maintenance team members to resolve daily

equipment breakdowns in shortest possible time and in safe working conditions.

• They plan and organize daily maintenance activities, demonstrate problem solving skills for

PM and breakdown abnormalities in Trim, chassis and finish areas.

• Maintaining Maintenance documentation, records, Check sheets, Daily Logs, abnormality

findings and co-ordination of spare part for equipment breakdown.

• Root Cause Analysis and plan permanent correctives actions for failures.
• Collaboration with area experts to resolve daily issues related to productivity, quality & other

process related issues.

• Responsible for TM Skill evaluation & training & development to enhance their skills.
• Responsible for team member shift schedule & leave management
• Communication with production team with timely response and actions as required
• Following breakdown escalation matrix and communication of actions taken.
• Co-ordination with multiple agencies on line to resolve the breakdown.
• Team member feedback collection, and planning spare parts and resources with approval of

shift leaders. Risk escalation communication to shift leaders.

Authority:

1. Stop production in case of major safety, severe equipment breakdown and quality issue.

2. Modification and optimization of non-critical machine parameter

3. Team member leave approval & Team member shift scheduling

4. Team member selection & Work allocation to team members

5. To define action plan for day-to-day breakdown

6. Updation of PM checkpoints based on day-to-day observations

Skills Required:

• Expert in Control Panel, PLC, HMI, Drives, Pilz relay, conveyors and Robots,
• Hydraulics, Pneumatics, Various Mechanical drives & Bearings
• Work prioritization, Manpower handling, Process product and equipment
• knowledge
• TPM, 5s, ISO, QMS, EMS, EnMS, Process audit, KVP
• Leadership, Decision making, Team work, Innovative thinking, Problem solving,
• Business Accumen
• Handling conflicts while working in a team
• Technical know-how of equipment operation and diagnostics for Trim, Chassis,
• Finish, Finish center.
• Thorough knowledge on line buffer system, contingency plans to minimize the
• impact of equipment breakdown.
• Know-how of provision of containment plans for every equipment/ tool /
• conveyor / tackles / fixtures to avoid lines loss.
• Working in situations of equipment failure and quick diagnostics
• Quick decision making and problem solving skills
• Understanding of car manufacturing process
• Understanding of buffer systems for managing issues till line start
• Art of persuasion, convincing skills and working in cross functional team like
• production, quality, analysis team.

Key Responsibilities &Tasks:

Maintenance:

1. Resolve day to day breakdown from all lines with best possible uptime.

2. Co-ordinate with production and with help of team members take necessary actions to avoid line

stoppages and equipment breakdown.

3. Communicate within the team, about the breakdowns, actions taken.

4. Plan and track the preventive maintenance of equipment on line with reference to master schedule.

5. Document the findings and update the PM Plan vs actual once PM is completed.

6. Take the feedback from team members and document the day to day breakdown activities from all lines.

7. Prepare a skill matrix for team member and make training plan for them.

8. Co-ordinate with other agencies, suppliers involved to solve the breakdowns.

Safety:

1. Instruct team members to perform their tasks in a safe manner.

2. Identify any hazard while performing maintenance activities.

3. Plan actions to counter these hazard.

4. Escalate any risk identified to shift leaders.

Quality:

1. Co-ordinate with production to ensure no defect is generated due to equipment.

2. Validate patrolling check sheet are filled by team members on daily basis.

3. Evaluate the effectiveness of work done by team members.

4. Support production for requirement of change on line or any small automations.

QMS; ISO 14001 (Environment MS); VDA 6.3; ISO 50001 (Energy MS):

1. Update & Maintain all auditable documents required to achieve QMS / Process audit Score and implement

action plan for non-conformities.

2. Implementation & documentation of Objectives of Energy and Environment Management System ISO 50001

&14001.

Documentation (Check sheets, verification sheets.) :

Updated PM records, Updated RCA, CAPA, WI

Updated Logbook, Updated Spare part status. Overtime Records of Team Members.

Total Productive Maintenance (TPM) and 5S:

Performs a daily check of the TPM and 5S activities of his subordinated teams;

Clear Red Tag on Daily basis and Send Records to TPM Co-coordinator.

Leave management:

Approve leaves of team members according to their respective balance as per Leave Management System

(electronically). Solve conflicts; communicate misuse to HR for all line team member