Position: Engineer Maintenance
Experience: 5 to 8 years
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)
- Handle 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
- Solid 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 fast, structured breakdown response teams for line‑stopping issues.
- Conduct RCA (Why‑Why, Fishbone, 8D) for chronic

📌 Engineer - Maintenance (Chennai)
🏢 Johnson Electric Group
📍 Chennai