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Key Responsibilities

1. Breakdown Maintenance

- Attend machine breakdowns and troubleshoot equipment failures.

- Conduct Root Cause Analysis (RCA) using Why-Why Analysis techniques.

- Identify defects and abnormalities and implement corrective actions.

- Restore equipment to operational condition within minimum downtime.

- Deploy corrective actions across similar machines to prevent recurrence.

- Coordinate with production and service engineers for machine restoration and improvement activities.

- Participate in daily maintenance review meetings and report maintenance issues.

- Support machine installation, shifting, and NPD-related maintenance activities.

1. Preventive & Predictive Maintenance

- Execute preventive maintenance activities as per the annual maintenance plan.

- Analyze equipment history before conducting preventive maintenance.

- Perform routine inspection of machines and equipment as per maintenance checklists.

- Carry out condition-based maintenance and equipment monitoring.

- Maintain and update TBM (Time-Based Maintenance) schedules and calendars.

- Inspect equipment and spare parts periodically and assess their condition and shelf life.

- Prepare predictive maintenance reports and records.

- Conduct periodic overhauls and preventive maintenance to minimize future breakdowns.

1. Spare Parts & Inventory Management

- Identify critical and non-critical spare parts.

- Ensure machine-wise spare parts availability as per maintenance requirements.

- Generate purchase requisitions (PR) for spare procurement.





- Coordinate with procurement and stores teams for timely availability of spares.

- Optimize inventory levels and reduce inventory carrying costs.

- Standardize common spare parts across equipment where feasible.

1. Cost Reduction & Continuous Improvement

- Implement cost-saving initiatives related to maintenance operations.

- Execute energy-saving projects to improve operational efficiency.

- Identify low-cost, high-life spare parts and maintenance solutions.

- Support Kaizen and continuous improvement initiatives.

- Reduce external service costs through skill development and in-house capability building.

1. Documentation & Compliance

- Update daily breakdown reports in SAP.

- Maintain machine history cards, preventive maintenance records, and predictive maintenance documentation.

- Ensure compliance with IATF, TS, and other quality management system requirements.

- Maintain 5S audit documents and reports.

- Prepare maintenance reports and performance metrics.

- Conduct training for apprentices, operators, and contract workers.

Required Skills & Competencies

- Preventive, Predictive, and Breakdown Maintenance

- Root Cause Analysis (RCA) & Why-Why Analysis

- TBM (Time-Based Maintenance)

- Condition-Based Maintenance (CBM)

- SAP PM Module

- Industrial Troubleshooting

- Spare Parts Management

- Inventory Control

- Kaizen & Continuous Improvement

- 5S and Lean Manufacturing

- IATF / TS Audit Compliance

- Cost Reduction & Energy Management

Preferred Qualification

- B.E./B.Tech/Diploma in Mechanical, Electrical, Mechatronics, or related Engineering discipline.

- Experience in automotive or manufacturing plant maintenance.

- Robust knowledge of industrial machines, equipment maintenance, and reliability engineering

📌 Maintenance Engineer (Pune)
🏢 Varroc
📍 Pune