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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.

2. 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.

3. 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.

4. 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.

5. 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.
- Solid knowledge of industrial machines, equipment maintenance, and reliability engineering

📌 Maintenance Engineer (Pune)
🏢 Varroc
📍 Pune