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

- 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.

- 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.

- 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.

- Breakdown Management Root Cause Analysis

- Lead fast, 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.

- 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.

- 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 strong troubleshooting capability for high speed automated equipment.

- Drive safety culture and compliance within the maintenance team.

- 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 Setting

- High volume, fast paced manufacturing environment

- 24/7 operations with critical uptime requirements

Hands on engagement with shop floor and automation systems

Disclaimer: This has been sourced from a public domain and may have been modified by Naukri.com to improve clarity for our users. We encourage job seekers to verify all details directly with the employer via their official channels before applying.

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