Position Title:
Department:
Focus Equipment:
Reports To:
Location:
Job Purpose
To ensure 100% availability and optimum performance of highly automated production lines driven by PLCs, industrial robots, compressors, air pumps, exhaust systems, water circulation pumps, and associated control panels through preventive maintenance, rapid troubleshooting, and continuous improvement.
Key Responsibilities (Tailored to Your Plant)
Preventive & Predictive Maintenance
- Execute daily/weekly/monthly PM checklists for:
- PLCs (Delta), HMIs, SCADA systems
- Industrial robots (Fanuc)
- Air compressors (screw / reciprocating), dryers, and air receiver tanks
- Vacuum pumps, exhaust blowers, and dust-collection exhaust systems
- Water pumps (centrifugal, submersible)
- All MCC / PCC / local control panels and field instrumentation
- Perform backup of PLC programs, robot programs, and HMI projects weekly.
- Conduct vibration monitoring on compressors, pumps, and robot bases; thermography on all electrical panels and motors.
Breakdown Response & Advanced Troubleshooting
- First responder for line stoppages caused by PLC faults, robot errors, sensor failures, servo drives, VFDs, or pneumatic systems.
- Diagnose and rectify faults in:
- PLC I/O modules, communication issues (Profibus, Profinet, EtherNet/IP, Modbus)
- Robot teach pendant errors, servo amplifier faults, reducer issues, cable breaks
- Compressor unloading faults, oil issues, pressure switch failures
- Air leaks, solenoid valve failures, FRL unit problems
- Water pump cavitation, seal failures, motor overloads
- Control panel tripping (MCB, MPCB, relays, contactors, overload relays)
- Use diagnostic tools: multimeter, oscilloscope, PLC software (TIA Portal, Studio 5000, GX Works), robot diagnostic software, pressure gauges, flow meters.
PLC Programming & Modifications
- Modify ladder logic / structured text for small process improvements and new changeovers.
- Add new I/Os, sensors, actuators, and safety circuits (Pilz, Sick light curtains).
- Integrate new equipment with existing PLC and SCADA systems.
Electrical Systems & Safety
- Maintain and troubleshoot 415V LT panels, VFD panels, servo drive panels, and safety PLCs.
- Strict adherence to LOTO, arc-flash safety, and permit-to-work system.
- Regular testing of ELCB/RCCB, earthing pits, and emergency stop circuits (especially robot cells).
Utilities & Critical Support
- 100% uptime of plant utilities:
- Compressed air system (78 bar)
- Vacuum and exhaust systems
- Process cooling water and chilled water loops
- Support new robot/line installations, FAT, SAT, and commissioning.
Documentation & Spare Management
- Maintain updated PLC program versions, robot backups, electrical drawings, and panel schematics in the server.
- Update CMMS (SAP / Maximo / custom) with failure codes, root cause, and actions.
- Manage critical spares: PLC cards, servo motors, robot reducers, compressor kits, pump mechanical seals, contactors, sensors.
Training & Continuous Improvement
- Train technicians on basic PLC fault finding, robot error reset procedures, and safe isolation.
- Lead RCA for repeated robot stoppages, compressor trips, or water pump failures.
- Implement TPM, 5S, and Kaizen in automation areas.
Required Qualifications & Experience
- B.E. / B.Tech in Electrical / Electronics / Mechatronics / Instrumentation Engineering
- 3–8 years hands-on experience in PLC & robot-based automated lines (automotive, consumer goods, pharma, or packaging plants preferred)
- Mandatory skills:
- Control panel maintenance
- VFDs (Delta), servo systems, and field instrumentation
- Reading electrical drawings and pneumatic diagrams
Work Conditions
- Rotational shifts + on-call for critical breakdown
