Electrical Engineer - Factory Maintenance

Role & responsibilities

The Electrical Engineer will be responsible for the operation, maintenance, troubleshooting, and continuous improvement of all electrical systems and equipment within the factory premises. This includes HT/LT power distribution infrastructure, CNC and PLC-based machine controls, industrial ovens, DG sets, APFC panels, and all associated electrical utilities. The role demands a hands-on professional capable of ensuring maximum uptime, safety, and energy efficiency across the plant.

Preferred candidate profile

1. HT Line & Power Distribution

• Oversee the operation and maintenance of HT (High Tension) electrical incoming supply, including HT breakers, CTs, PTs, metering panels, and protection relays.
• Ensure compliance with State Electricity Board regulations and liaise with authorities for HT line-related matters, shutdowns, and inspections.
• Coordinate annual preventive maintenance and testing of HT equipment including relay testing, insulation resistance, and oil filtration.

Transformer Maintenance

• Manage routine maintenance and condition monitoring of power transformers, including oil level checks, BDV testing, winding resistance, and temperature monitoring.
• Plan and execute annual transformer maintenance schedules and ensure availability of critical spares such as bushings, gaskets, and breather silica gel.
• Maintain transformer protection systems including Buchholz relay, OTI/WTI, PRV, and surge arrestors.

MCC, PCC & APFC Panels

• Ensure reliable operation of Main MCC (Motor Control Centre), PCC (Power Control Centre), and sub-distribution panels.
• Carry out periodic inspection, thermography, busbar torquing, and maintenance of all LT panels.
• Maintain APFC (Automatic Power Factor Correction) panels to keep power factor above 0.99 and minimise penalty from the electricity board.
• Monitor and replace capacitor banks, contactors, and APFC relay controllers as per maintenance schedules.

DG Set Operation & Maintenance

• Ensure DG sets are maintained in ready-to-start condition for seamless power backup during grid failures.
• Manage DG AMC contracts, fuel monitoring, load bank testing, and AMF (Auto Mains Failure) panel functionality.
• Maintain synchronisation panels where multiple DG sets are installed.

. CNC & PLC Based Machine Maintenance

• Troubleshoot and maintain electrical systems of CNC machines, including servo drives, spindle drives, VFDs, encoders, proximity sensors, and limit switches.
• Diagnose and rectify faults in PLC-based automation systems, including I/O modules, communication networks (Profibus, Profinet, Modbus), and HMI interfaces.
• Maintain and backup PLC programs and CNC parameters; coordinate with OEM service engineers during major breakdowns and retrofits.
• Ensure proper grounding, shielding, and EMC compliance of CNC and PLC installations.

Industrial Oven Maintenance

• Maintain electrical systems of industrial ovens, including heating elements, thyristor / SCR controllers, PID temperature controllers, and thermocouples/RTDs.
• Ensure proper functioning of safety interlocks, over-temperature protection, and alarm systems on all oven installations.
• Troubleshoot control panel issues including contactors, timers, and solid-state relays used in oven heating circuits.

Preventive & Predictive Maintenance

• Develop, implement, and continuously improve the Preventive Maintenance (PM) schedule for all electrical assets.
• Deploy predictive maintenance techniques such as IR thermography, insulation resistance testing, vibration analysis for motors, and power quality analysis.
• Maintain a comprehensive equipment history log and use CMMS (Computerised Maintenance Management System) for tracking work orders, spares, and downtime.

Safety, Compliance & Energy Management

• Ensure strict compliance with Electrical Safety rules, IS standards, IE Act, and CEA regulations applicable to HT installations.
• Implement and enforce LOTO (Lock out Tag Out) procedures, work permit systems, and arc flash safety protocols.
• Conduct periodic earth resistance testing, lightning protection audits, and insulation checks.
• Drive energy conservation initiatives, monitor energy KPIs (kWh/unit of production), and identify opportunities for demand-side management.
• Coordinate with the Electrical Inspector and statutory authorities for periodic inspections, licence renewals, and compliance certifications.

Team Management & Coordination

• Lead and supervise a team of electricians and electrical technicians; assign daily tasks, monitor performance, and ensure skill development.
• Coordinate with production, quality, and other departments for planned shutdowns and maintenance windows.
• Manage electrical spare parts inventory and procurement in coordination with the stores and purchase departments.

Prepare and maintain electrical SLDs (Single Line Diagrams), panel schedules, cable schedules, and equipment documentation.