Engineer, Maintenance

Experience: 5 to 8 years

Location: India, Chennai

Skills: high-speed automated assembly lines, DC motor manufacturing processes, PLC, HMI, SCADA, servo drives, vision systems, sensors, vibration analysis, thermal analysis, current signature analysis, MTTR, MTBF, RCA, Why-Why, Fishbone, 8D, CAPA, lean manufacturing, TPM, Kaizen, OEE, safety standards, ISO, IATF, EHS

Position: Engineer Maintenance
Role Purpose
Engineer – Maintenance is responsible for ensuring maximum uptime, reliability, and performance of high‑speed automated DC motor assembly lines. The role focuses on maintaining and improving integrated, multi‑station single‑piece‑flow assembly lines with MES systems, while driving predictive, preventive and breakdown maintenance excellence.

Key Responsibilities
1. Assembly Line & Equipment Maintenance
Ensure >99% line availability for fully automated DC motor assembly lines operating at 1‑second cycle time. Lead maintenance of processes including:
• Armature/coil winding machines
• Fusing machines
• Soldering stations (automatic soldering, induction soldering)
• Motor performance testing stations (electrical, torque, RPM, noise, vibration)
Manage maintenance for 40+ stations integrated & connected through single piece flow conveyor systems. Own troubleshooting of complex interlocks, station handshakes, and line balancing issues.

2. Automation, Controls & Systems
Strong ownership of PLC, HMI, SCADA, servo drives, vision systems, safety PLCs, and sensors. Diagnose and resolve high‑speed automation faults impacting takt time and throughput. Work closely with automation vendors and OEMs for:
• Root cause analysis
• Software modifications
• Cycle time improvements
Ensure robust backup, version control, and change management for automation programs.

3. Preventive & Predictive Maintenance
Define and deploy Preventive Maintenance (PM) and Predictive Maintenance (PdM) strategies suitable for high‑speed lines. Drive condition monitoring (vibration, thermal, current signature analysis)



for critical stations. Reduce MTTR and increase MTBF through structured maintenance practices. Maintain and improve equipment OEE.

4. Breakdown Management & Root Cause Analysis
Lead quick, structured breakdown response teams for line‑stopping issues. Conduct RCA (Why‑Why, Fishbone, 8D) for chronic and repetitive failures. Implement permanent corrective and preventive actions (CAPA). Track breakdown data and lead continuous improvement initiatives.

5. Continuous Improvement & Cost Optimization
Drive cycle time stability in 1‑second takt environments. Support lean manufacturing, TPM, Kaizen, and reliability improvement projects. Reduce maintenance costs through:
• Spare parts optimization
• Reliability redesign
• Vendor performance management
Support capacity expansion, line duplication, and automation upgrades.

6. Team Leadership & Capability Building
Lead, coach, and develop a team of maintenance engineers, supervisors, and technicians. Ensure round‑the‑clock maintenance coverage aligned to production shifts. Build solid troubleshooting capability for high‑speed automated equipment. Drive safety culture and compliance within the maintenance team.

7. Spares, Documentation & Compliance
Ensure critical spares availability with optimal inventory levels. Maintain updated equipment documentation, SOPs, PM schedules, and electrical drawings. Ensure compliance to safety standards, quality systems, and audit requirements (ISO, IATF, EHS).

Key Skills & Competencies
Technical Skills
Expertise in high‑speed automated assembly lines (≤1 second cycle time)
Strong knowledge of DC motor manufacturing processes
Advanced troubleshooting of:




• PLCs & motion control systems
• Servo drives & robotics
• Vision systems and functional testing stations
• Conveyor systems with single piece flow
• Electrical, mechanical, pneumatic, and control systems integration
Behavioral & Leadership Skills
• Strong problem‑solving and decision‑making abilities
• Ability to work under high‑pressure, zero‑tolerance downtime environments
• Effective communication with production, quality, and engineering teams
• Results‑driven, hands‑on leadership style

Qualifications & Experience
• Bachelor’s Degree in Electrical / Mechanical / Mechatronics / Automation Engineering
• 5–8 years of maintenance experience in:
• Automotive
• Motor manufacturing
• High‑speed automated assembly lines
• 5+ years in a maintenance leadership/managerial role preferred

Key Performance Indicators (KPIs)
• Line availability / OEE
• MTTR / MTBF
• Breakdown frequency and severity
• PM compliance
• Maintenance cost vs budget
• Safety incidents (zero tolerance)

Working Environment
High‑volume, fast‑paced manufacturing environment
24/7 operations with critical uptime requirements
Hands‑on engagement with shop floor and automation systems

Come join our global, inclusive & diverse team
Our purpose is to improve the quality of life of everyone we touch through our innovative motion systems. We are a truly global team bound together by our shared values. Our culture is built on the diversity, knowledge, skills, creativity, and talents that each employee brings to the company. Our people are our company’s most valuable asset. We are committed to providing an inclusive, diverse and equitable workplace where employees of different backgrounds feel valued and respected, regardless of their age, gender, race, ethnicity or religious background. We are committed to inspiring our employees to grow, act with ownership and find fulfilment and meaning in the work they do.

📌 Engineer, Maintenance (Chennai)
🏢 Johnson Electric
📍 Chennai