Front End Engineer

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JOB TITLE : : Front End Engineer

REPORTING TO : Mechanical lead

JOB SUMMARY

Front End Engineer primary role is to focus on OEE of front end Equipment in can making line. He will focus on Daily operation, process and maintenance issues of Cupper, Bodymakers trimmers and take corrective actions on time. He will plan the front end resources and allocate them to focus on Periodic inspection and maintenance, predictive maintenance and corrective Maintenance activities in front end. He will gain mastery in Process troubleshooting and maintenance of Cupper Bodymakers and trimmers, train the team and get the best out of them. He will act as a link between Shift Manager, Area Leader, maintenance supervisor, toolroom, maintenance engineers, Electrical engineers, spareparts stores and co-ordinate all the activities of Maintenance, improvements, TPM, 5’s activities in the area. He will strive hard to achieve area KPI’s through collaboration, teamwork and planning. He will play key role in size changeovers and achieve best in class changeover time in the front end.

KEY ACTIVITIES / RESPONSIBILITIES

• Responsible for Planning of and execution of preventive Maintenance activities in Cupper Bodymakers and trimmers majority in Minster cupper, Stolle BM’s. Tracks the maintenance compliance on periodical basis and take corrective actions to bridge the gap.
• Ensures Front end equipment are operating at designed / optimum speed. Makes action plan / corrective plan and gets the equipment back in optimum operating conditions / speed.
• Checks the daily operations log book and note down the actions needed and includes in action list to action upon. Checks for daily maintenance compliance, randomly checks if the daily Pm’s are actually done on line and feedback to operating team. Compiles daily PM’s compliance in front end and send out report on periodic basis.
• Responsible for hydraulic oil consumption in the front end, tracks and takes corrective actions for deviations.
• Checks and control critical process indicators in front end such as tramp oil concentration, coolant concentration, short can rate etc., and take timely actions to highlight and correct it.
• Responsible for corrective Maintenance on front end, either attend personally or allocates resources, and get the equipment back in operation with least possible downtime.
• Plan for spareparts. Study the spareparts needed for the Bodymakers and cupper forehand and plan the spares on time. Gives input to Maintenance supervisor / Spareparts stores engineer to set Minimum / maximum of spareparts used in the Equipment. Works closely with spareparts stores to arrange for spareparts.
• Tracks and controls the consumable spares consumption (such as stripper rings, seals, filters etc.).
• Tracks and controls spares used in the front end. Attends daily engineering meetings and justifies for the spares consumed.
• Responsible for the tooling consumption, timely change of tooling upon reaching their optimum life. Works closely with toolroom for availability of all the tooling on time.
• Responsible for ASSEMBLED SPARES. (Domer, Rear piston, front Piston, Cartridges, spindles) Keeps the assembled spares ready near line.
• Responsible for die set maintenance. Gains Mastery in Die set maintenance and performs periodic inspections / Maintenance as needed.
• Responsible for Size changeovers in cupper, Bodymakers and trimmers. Organizes and inspect change parts prior to changeovers. Plan and organize resources to ensure Size change is done within specified time and up in running smoothly with least issues.
• Follows and maintain organization’s SOPs and safe working practices. Comply with any legal, environmental and safety , BRC requirements and/or checks
• To actively participate in companies Continuous Improvement initiatives e.g. Lean Manufacturing, Six Sigma, SMED, 5 S, ISO, etc. Conduct lean manufacturing activities and participate in audits as per company requirements.
• Maintain housekeeping to the standard defined in the Housekeeping and Hygiene procedure.

Responsible for all the standard and special tools used in the front end. Ensures effective utilization of tools and tackles and prevent misuse of same.

EDUCATIONAL REQUIREMENTS

Diploma/Engineering in Mechanical engineering or toolroom technology

PREVIOUS EXPERIENCE

• 8+ Years maintenance / repair experience in manufacturing background in a high speed, high volume continuous process plant with hydraulic and Mechanical presses. Such as automotive ancillary
• Successful track record in mechanical maintenance/ Hands on experience is must.
• Experience in machine shop, lathe, Milling, surface Grinding.

SKILLS & COMPETENCIES REQUIRED

• Computer literacy and the ability to generate reports. Ability to read, understand and develop engineering drawings.
• Analytical skills to interpret numerical data

Working knowledge of Health and Safety work practises

LANGUAGES REQUIRED

English

Local languages.

KRA / KPI OF THE ROLE (measurable responsibilities)

Front end OEE

Short Can rate

Maintenance compliance

Hydraulic oil consumption

Changeover time

Breakdown percentage

Key responsibilities include:

• Planning of and execution of preventive maintenance activities in cupper bodymakers and trimmers, tracking the maintenance compliance on periodical basis and taking corrective actions to bridge the gap
• Ensuring front end equipment are operating at designed / optimum speed, making action plan / corrective plan and getting the equipment back in optimum operating conditions / speed.
• Checking the daily operations log book and note down the actions needed and checking for daily maintenance compliance
• Responsible for hydraulic oil consumption in the front end, tracks and takes corrective actions for deviations.
• Checking and controlling critical process indicators in front end such as tramp oil concentration, coolant concentration, short can rate etc., and taking timely actions to highlight and correct it
• Responsible for corrective maintenance on front end
• Planning for spare parts, studying the spare parts needed for the bodymakers and cupper forehand and planning the spares on time
• Responsible for the tooling consumption, timely changing of tooling upon reaching their optimum life and working closely with toolroom for availability of all the tooling on time
• Keeping the assembled spares ready near line and being responsible for assembled spares (dormer, rear piston, front piston, cartridges, spindles)
• Following and maintaining organization’s SOPs and safe working practices, complying with any legal, environmental and safety , BRC requirements and/or checks
• Participating in companies Continuous Improvement initiatives e.g. Lean Manufacturing, Six Sigma, SMED, 5 S, ISO and conducting lean manufacturing activities and participating in audits as per company requirements

Experience and skills required:

• Graduate / Diploma in Mechanical engineering or toolroom technology
• Job related experience for minimum 8 years in maintenance / repair in manufacturing background in a high speed, high volume continuous process plant with hydraulic and mechanical presses
• Hands on experience in maintenance / alignment / set up / trouble shooting of gearboxes, complex assemblies, hydraulic circuits, heavy duty mechanical power press and similar
• Experience during commissioning and startup of equipment will be added advantage
• Advanced knowledge of MS Office and preferable knowledge of SAP
• Fluent in English

Ball Corporation is an Equal Opportunity Employer. We actively encourage applications from everybody, regardless of gender, age, ethnicity, faith, ability, or orientation.

When you join Ball you belong to a team of over 16,000 members worldwide. Our products range from infinitely recyclable aluminium cans, cups to aerosol bottles solutions that enable our customers to contribute to a better world.
Each of us has a deep commitment to diversity and inclusion which is the foundation of our culture of belonging. Everyone at Ball is making a difference by doing what we love. Because what we create may change, but what we will always make is a difference.

Please note the advertised job title might vary from the job title on the contract due to local job title structure and global HR systems.

No agencies please.