Paintshop Maintenance

1. POSITION DETAILS:

Position Title:

Engineer /Sr. Engineer

Reports to Position:

Head of the Dept

Department:

Maintenance / Paint Shop

2. OBJECTIVE:

Responsible for the preventive, predictive, and breakdown maintenance of paint shop equipment and utilities to ensure smooth operations with minimum downtime and adherence to safety and quality standards.

3. KEY ACCOUNTABILITIES:

Description

1.Equipment Maintenance:

Conduct routine preventive and predictive maintenance for

• Pretreatment (PT) & Electro Deposition (ED) systems
• Paint booths (Primer, Base coat, Clear coat)
• Robots (ABB), all Ovens and conveyors
• Air handling units (AHU), chillers unit
• Troubleshoot electrical, mechanical, and automation issues.

2. Breakdown Management:

• Respond to and resolve equipment breakdowns with minimal production loss.
• Root cause analysis and permanent corrective actions (RCA & CAPA).

3. Continuous Improvement:

• Implement Kaizen, TPM (Total Productive Maintenance), 5S, and energy-saving initiatives.
• Improve MTBF (Mean Time Between Failures) and reduce MTTR (Mean Time To Repair).

4. Spare Parts & Inventory:

• Manage critical spares inventory for paint shop equipment.
• Raise PRs, monitor consumption, and coordinate with stores/purchase.

5. Compliance & Documentation:

• Maintain maintenance logs, checklists, and shutdown schedules.
• Ensure compliance with ISO/TS/IATF standards, audits, and EHS norms.

6. Vendor & Project Coordination:

• Coordinate with OEMs and service providers for equipment servicing, and upgrades.
• Support any new project commissioning, modifications, and line expansions.

4. COMMUNICATIONS & WORKING RELATIONSHIPS:

• Daily coordination to monitor equipment performance and respond to downtime issues.
• Joint efforts to analyze losses impacting OEE (Availability, Performance, Quality).
• Collaborate on quality-related machine performance issues.
• Support in root cause analysis of quality losses due to equipment faults.
• Coordinate planned maintenance and shutdown activities.
• Share best practices across departments for improving OEE.
• Work on process improvements and new equipment layouts for better productivity.
• Ensure compliance with safety and plant standards during work.
• Report KPIs, trends, and improvement projects regularly.

5. Performance INDICATORS (INDICATIVE):

• Increase in Overall Equipment Effectiveness (OEE) – Target-based (% improvement per quarter/year).
• Reduction in equipment-related downtime (Availability losses).
• Mean Time Between Failures (MTBF) – Higher MTBF indicates better reliability.
• Mean Time To Repair (MTTR) – Lower MTTR indicates faster recovery.
• Energy consumption per painted unit – improvement through better equipment control.
• Number of Kaizen/Lean/TPM initiatives implemented.
• Zero unsafe maintenance practices – Number of safety incidents during maintenance.
• Compliance with safety audit findings and regulatory norms.
• Reporting dashboards maintained and updated for equipment KPIs.

6. QUALIFICATIONS, eXPERIENCE & SKILLS:

Qualification : Diploma/ Engineering

Experience :

Paint shop Automotive OEM or Tier-1 supplier

7. COMPETENCIES, CORE VALUES, BEHAVIOURS: -

• Strong knowledge of paint shop processes and equipment
• Strong knowledge on the Robot troubleshooting skills
• Hands-on experience in automation (PLC, HMI – Siemens/Mitsubishi)
• Knowledge of HVAC systems and water treatment processes
• Problem-solving and analytical skills
• Familiarity with TPM and root cause analysis tools
• Good communication and team coordination skills