Senior Engineer Maintenance (PLC and Automation)

Job Summary: TATA FICOSA Automotive Systems Pvt Ltd is currently seeking a seasoned and dynamic Senior Engineer / Asst. Manager – Maintenance to bolster our team at the Sanand facility in Gujarat. The ideal candidate should possess extensive experience in the Maintenance department within the automotive industry, with a strong emphasis on expertise in Hydraulics, Pneumatics, PLC, HMI, Drives, TQM, Kaizen, ESG (Environmental, Social, and Governance) initiatives.

Job Description:

1. Hands-on experience in Automation System: • Programming, Installation, commissioning & troubleshooting of PLC, HMI, (Preferably Delta & siemens Make). • Expertise in Delta make, PLC, HMI, VFD & servo. • Installation, commissioning & troubleshooting of VFD, Servo drive. (Delta & siemens make.) • Knowledge & hands on experience in various types of analogue and digital sensors. • Experience in different types of communication protocols. Modbus, Ethernet & can open. • Knowledge & experience in different types of 3rd party devices communication with PLC, HMI printer etc. • Experience in control, power panel wiring & troubleshooting. • Knowledge & experience in machine barcode traceability system & LabVIEW. • Knowledge & experience in different types of LVDT sensor, proximity sensors, photo sensors read switches, limit switches, load cell, Printers Etc. • Knowledge in Industry 4.O & MES system. • Software proficiency: Delta PLC Software- WPL Soft, ISP Soft, Delta HMI- DOP Soft, Delta Servo -ASDA- A2 & A3 Series, Siemens PLC-TIA Portal, VFD- Starter Etc.

2. Equipment Up Time Optimization: • Strategize spare parts inventory for maintenance activities. • Monitor inspection and maintenance procedures closely. • Implement corrective actions promptly to ensure maximum machine uptime. • Quick Attending daily breakdowns and emergencies related to machines & utilities. • Supervise condition of all equipment’s & potential upgradation to reduce downtime & repetitive failures • Data collection & analysis of machine breakdown data. • Ensuring maximum uptime & minimum downtime of machines. • Maintain MTTR & MTBF.

3. Preventive and Predictive Maintenance: • Schedule preventive maintenance tasks for all machinery. • Allocate necessary resources for maintenance activities. • Analyse machine data to propose predictive maintenance measures. • Oversee maintenance operations to minimize machine downtime. • Ensured preventive & predictive maintenance should be carried out as per plan.• Maintain all maintenance documents. • Experience in audit compliance handling process.

4. New Machine Installation: • Trail, erection& commissioning of new machines. • Store the updated PLC program backups. • Maintain Machines manual, electrical, mechanical & pneumatic drawing. • Correct all required modifications in PLC & HMI from supplier during machine installation process.

5. Spare parts Management: • Ensuring adequate spare required for machine & equipment’s. • Daily tracking of spare stock. • Ensuring zero maintenance due to spare control. • Knowledge & experience in PR, PO Process in SAP system. • Suppliers follow up for on time receiving the spares.

6. Safety System: • Follow the proper LOTO procedure while working on machines • Adhere to the safety standards & legal regulations while executive maintenance management task & program.

7. People Management: • Establish a skill inventory within the maintenance function. • Delegate responsibilities to junior staff and ensure adherence to processes. • Coach and mentor junior team members for skill enhancement. • Conduct training sessions to educate junior staff on functional aspects.

8. SAP Maintenance module • Knowledge & hands-on experience in SAP maintenance module.

9. Continuous Improvement Initiatives: • Ensure effective implementation of Poka-yoke methods. • Spearhead projects aimed at cost reduction. • Explore opportunities for localizing imported machine spares to minimize maintenance costs. • Energy saving project implementation. • Implementation of effective kaizens for process improvement & quality improvement. • Existing machine program modification for reducing minor stoppages & repetitive failures.

Qualifications and Skills:

• Essential: B.E. in Electrical/Electronic Engineering with 4 - 5 years of experience in the Automotive Industry.

• Proven expertise in Hydraulics, Pneumatics, PLC, HMI, Drives, TQM, Kaizen.