Injection Moulding Maintenance Engineer

Job Description

Job Title: Injection Moulding Maintenance Engineer

Department: Maintenance

Job Purpose

To lead the complete maintenance and management of injection moulds, ensuring their availability, reliability, and performance. The role requires hands-on technical expertise in mould repair, changeover, and preventive maintenance, as well as strong managerial skills to lead a team, drive efficiency, and ensure alignment with production and quality goals.

Key Responsibilities

Mould Maintenance & Repair

• Lead and oversee all preventive, predictive, and breakdown maintenance of injection moulds.
• Supervise mould repair activities including welding, polishing, fitting, alignment, and cooling line cleaning.
• Monitor and ensure mould life tracking with accurate documentation.
• Establish and implement root cause analysis (RCA) for recurring mould issues.

Mould Changeovers

• Plan, coordinate, and supervise mould change activities to ensure quick and smooth changeovers.
• Develop and implement standard work procedures for mould setting and removal.
• Minimize downtime during mould changes through team training and effective planning.

Lathe Machine Operations & Maintenance

• Oversee all lathe machine operations related to mould repair and component fabrication.
• Supervise turning, facing, drilling, boring, threading, and grooving work for mould components.
• Ensure accurate machining of spares and inserts as per engineering drawings.
• Plan and schedule lathe jobs to support mould maintenance and urgent breakdown requirements.
• Maintain calibration and precision of lathe machines through regular servicing.
• Train team members on safe operation, tool setting, and proper use of cutting tools.
• Implement preventive maintenance for lathe machines to reduce downtime.
• Ensure proper storage and management of cutting tools, jigs, and fixtures.
• Monitor machining quality to maintain tolerances and finish required for injection mould parts.
• Drive continuous improvements in machining productivity, cost reduction, and tool life.

Preventive & Predictive Maintenance Systems

• Develop and execute preventive maintenance schedules for all moulds.
• Implement predictive maintenance techniques (wear analysis, inspection reports, condition monitoring).
• Maintain mould history records for traceability and performance analysis.

Team Leadership & Development

• Lead, supervise, and train the mould maintenance team (technicians, fitters, helpers).
• Assign daily tasks, monitor performance, and ensure accountability.
• Provide technical guidance and mentoring to build internal capability.
• Foster a culture of discipline, teamwork, and continuous learning.

Coordination with Other Departments

• Work closely with the production team to plan mould availability as per production schedules.
• Collaborate with the quality department to ensure product quality is maintained.
• Coordinate with the procurement/store team for mould spares, consumables, and tools.

Documentation & Reporting

• Maintain complete records of mould maintenance, repairs, breakdowns, and spares consumption.
• Prepare and present regular maintenance performance reports to management.
• Monitor and report on mould downtime, MTTR (Mean Time to Repair), and MTBF (Mean Time Between Failures).

Continuous Improvement & Cost Control

• Drive Kaizen / 5S / Lean practices in the mould maintenance area.
• Identify and implement projects to increase mould life and reduce maintenance costs.
• Suggest and implement design modifications for mould improvements.
• Ensure optimal utilization of resources (manpower, tools, and spares).

Health, Safety & Compliance

• Ensure all mould maintenance activities are carried out with strict adherence to safety standards.
• Conduct regular safety training and audits for the team.
• Comply with ISO, IATF, or other quality management systems relevant to injection moulding.

Qualifications & Experience

• Diploma/Degree in Mechanical, Plastic, or Tool Engineering.
• Strong technical knowledge of mould repair, fitting, polishing, hot runners, cooling systems, and hydraulics.
• Proven experience in mould changeovers, breakdown analysis, and preventive maintenance.
• Familiarity with TPM (Total Productive Maintenance) and lean manufacturing principles.

Skills & Competencies

• Strong leadership and team management skills.
• Hands-on problem-solving and troubleshooting ability.
• Excellent planning, organizing, and time management skills.
• Good communication and coordination skills across departments.
• Ability to work under pressure and meet production deadlines.