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 quick, structured breakdown response teams for line stopping issues.
Conduct RCA (Why Why, Fishbone, 8D) for chronic and repetitive fai

📌 Engineer Maintenance Chennai
🏢 Johnson Electric
📍 Chennai