Responsible for Plan, Improve & Implement the preventive & breakdown maintenance activities by equipment upgradation, optimum utilization & on time availability of ready to use resources & adding value through cost saving & improvement for specific section of the plant.
1.Preventive Maintenance:
Plan preventive maintains in coordination with production team for Zero Breakdown and ensure 100% availability of machines and equipments.
Drive technical changes in preventive maintenance by considering the breakdown maintenance.
Verifying Preventive Maintenance check sheet on daily & weekly basis to ensure PM as per the plan
Making machine /Equipment available for preventive maintenance as per plan.
Verifying equipment inspection check sheets to identify abnormalities and taking the necessary action to overcome on that abnormalities by making required part available, installation of part & servicing of that equipment / machine.
Doing MTBF (Mean Time Between Failure) & MTTR (Mean Time to Repair) analysis and taking counter measure actions
Following and updating TBM calendar for timely basis inspection to increase the life of spare part and machine equipment.
Should align all the plan according to Quality Systems Requirements
Club visits of Manufacturere /AMC provider during PM schedule
2.Breakdown Maintenance
Attending the major breakdown maintenance to understand the exact problem by doing why-why analysis for taking counter measures
Guide for counter measure activity after breakdown analysis like, restoring the defective parts & removing the abnormalities, taking trail of equipment to ensure normal functioning of the equipment etc.
Review and analyze the day to day breakdown report & providing guidance to team as and when required.
Monthly review of break down report to understand the occurrence & root cause for reducing MTTR & increasing MTBF.
Prepare / suggest counter measure to prevent occurrence of the same problem/abnormality & ensure Horizontally deployment of the same through maintenance engineer.
Develop local service provider for small repair Job in accord with Purchase
3.Spares Management
Identifying critical and non-critical spare parts & time to time updating the spare part list as per requirement.
Management of Spare part for consumable spares, Wearing spares, electronic spares & electrical switch gears.
Controlling consumption of consumable, spare part and stock items.
Identification of Indigenous spare part for cost reduction
4.Cost Saving & Energy Conservation
Reducing inventory and saving cost by converting imported to indigenous, refurbishing and reuse, developing local vendors & alternate sources, also by inventing newest technology useful for company
Interacting with service engineers & doing market research to identify the low cost & long-life parts & materials to reduce the cost of material and parts.
Reducing service cost by inhouse training of maintenance team.
Identifying the power wastage & plan for energy conservation through reduction of energy consumption, reuse of energy, circuit modification, using natural resources & alternate energy efficient resources.
5.Modification & Upgradation
Identifying absolute & old equipments, machinery, spare parts and upgrading them as per new technology
Upgrade and improve absolute machines though system modification as per the customers requirements and KAIZEN.
Modification of the machine for improving MTTR & MTBF through analysis of past breakdowns and week design identification.
Providing advance tools like Bearing pooler, hydraulic Jack, hydraulic trollies, lifter, multi-function meters to reduce breakdown hours.
Should have small team to perform all Kaizen ideas, suggestions safety requirements
6.Manpower Management & Training
Prepare manpower plan & weekly shift schedule & Monitor shift wise manpower availability & take necessary actions in case of manpower shortage to avoid productivity loss.
Identify & escalate disciplinary issues to eliminate further losses.
Identification of technical & soft skill requirements to develop and train manpower accordingly.
Training existing & new manpower on system implementation.
7.Vendor & Service Management
Identify and develop compatible vendors for service solutions, Machine Upgradation, Tool Room requirements, electronic services and upgradation & coordinating with vendors on timely basis to resolve problems, changing parameters Taking follow-up for payment of vendor
8.System Implementation and documentation
Implementing systems like QMS, IATF, TS, 5S, TPM, DWM. Preparing the documentation and presentation of the same as per Statutory Requirement, audit requirement, management review, value working.
Reviewing and maintaining records of all maintenance related activities in SAP
Comply and percolate the statutory reequipments like OSHAS, EMS, Safety, MSEB.
Support in analysis of extracted IOT data and produce actionable insights for decision making
