SR. MAINTENANCE ENGINEER

Department: Maintenance / Engineering

Position: Maintenance Engineer

Reports To: HOD

Location: Sheet Metal Manufacturing Plant

Industry: Automotive / Engineering / Sheet Metal Components

Key Responsibilities

A. Maintenance Planning & Execution

Develop and implement annual, monthly and daily maintenance plans.

Ensure preventive and predictive maintenance is carried out as per schedule.

¢ Minimize machine breakdowns and production downtime.

¢ Monitor MTTR, machine availability and maintenance efficiency.

¢ Establish effective breakdown-response systems.

¢ Analyze recurring breakdowns and implement permanent corrective actions.

¢ Maintain equipment history and maintenance records.

B. Sheet Metal Machinery Maintenance

Responsible for maintenance of

¢ Mechanical / hydraulic / pneumatic power presses.

¢ Press brakes and shearing machines.

¢ Spot welding, MIG and other welding equipment.

¢ Robotic welding systems, where applicable.

¢ Compressors, air dryers and pneumatic systems.

¢ Pumps, motors, gearboxes and conveyors.

¢ EOT cranes, hoists and material-handling equipment.

¢ DG sets, electrical panels and distribution systems.

¢ HVAC, cooling systems and other utilities.

¢ Plant electrical, mechanical and utility infrastructure.

C. Electrical & Automation

¢ Ensure preventive maintenance of HT/LT electrical systems.

¢ Monitor electrical panels, MCCs, PCCs, transformers, motors and drives.

¢ Ensure PLC, HMI, sensors, VFD and automation-system reliability.

¢ Coordinate troubleshooting of electrical and automation failures.

¢ Maintain proper electrical safety and statutory compliance.

¢ Monitor power consumption and identify energy-saving opportunities.

D. Preventive & Predictive Maintenance

¢ Prepare equipment-wise preventive-maintenance checklists.





¢ Establish maintenance frequencies based on OEM recommendations and machine history.

¢ Implement condition monitoring such as vibration, temperature, oil condition and electrical health checks where applicable.

¢ Ensure timely replacement of wear parts, bearings, seals, belts, chains and other critical components.

¢ Develop critical-spares and preventive-replacement plans.

E. Breakdown Management

¢ Lead the maintenance team during major breakdowns.

¢ Ensure quick response and restoration of production.

¢ Conduct Root Cause Analysis (RCA) for major and repetitive failures.

¢ Implement CAPA to prevent recurrence.

¢ Track breakdown hours and identify top loss-making machines.

F. Dies, Fixtures & Tooling Support

¢ Coordinate maintenance and repair of production dies, fixtures and tooling.

¢ Ensure timely availability of dies and fixtures for production.

¢ Improve die/fixture life through preventive maintenance.

¢ Coordinate with Tool Room, Production and Quality teams for recurring tooling issues.

G. Spare Parts & Inventory Management

¢ Identify critical machine spares and maintain minimum stock levels.

¢ Control maintenance inventory and avoid unnecessary purchases.

¢ Develop alternate/local sources for critical components.

¢ Review spare consumption and obsolete inventory.

¢ Coordinate with Purchase and Stores for timely procurement.

H. Team Management

¢ Lead, train and develop maintenance engineers, supervisors, electricians, fitters and technicians.

¢ Allocate manpower according to shift and equipment requirements.





¢ Establish transparent responsibilities and escalation procedures.

¢ Conduct skill-gap analysis and technical training.

¢ Ensure discipline and adherence to maintenance procedures.

I. Safety & Compliance

¢ Ensure compliance with plant safety procedures.

¢ Implement LOTO (Lockout/Tagout) practices during maintenance.

¢ Ensure safe working practices for electrical, mechanical, welding and height-related maintenance activities.

¢ Conduct periodic safety inspections.

¢ Ensure statutory inspections and certifications of applicable equipment such as cranes,

pressure systems and electrical installations.

¢ Investigate maintenance-related accidents and implement corrective actions.

J. Cost Control & Energy Management

¢ Prepare and control the maintenance budget.

¢ Reduce breakdown, spare-parts and repair costs.

¢ Monitor maintenance cost per machine / production unit.

¢ Identify energy-saving opportunities.

¢ Reduce compressed-air leakage, power losses and utility wastage.

¢ Evaluate repair-vs-replacement decisions for major equipment.

K. Continuous Improvement

¢ Implement TPM, 5S, Kaizen and Lean Maintenance practices.

¢ Improve OEE through better machine reliability.

¢ Identify chronic losses and develop improvement projects.

¢ Standardize maintenance procedures and checklists.

¢ Drive automation and condition-monitoring initiatives where economically justified.

L. Documentation & Reporting

Maintain and review

¢ Preventive-maintenance schedules.

¢ Breakdown reports.

¢ Machine history cards.

¢ MTBF / MTTR reports.

¢ Machine availability reports.

¢ Spare-parts records.

¢ Maintenance cost reports.

¢ RCA and CAPA reports.

¢ Annual maintenance plans and budgets.

¢ Utility consumption reports.

¢ Statutory inspection records.

📌 Senior Maintenance Engineer (Manesar)
🏢 Horizon Industrial Products
📍 Manesar