JOB DESCRIPTION – MAINTENANCE ENGINEER

Department: Maintenance
Designation: Maintenance Engineer
Reporting To: Maintenance Head / Plant Head / General Manager
Industry: Plastic Injection Moulding – Automotive Components
Location: Mysore

1. JOB PURPOSE

To ensure the safe, reliable and efficient operation of all plastic injection moulding machines, moulding auxiliaries and associated electrical, electronic, hydraulic, mechanical and utility systems.

The Maintenance Engineer shall have in-depth practical knowledge of PLC, Electrical, Hydraulics and Mechanical systems and shall be capable of independently diagnosing faults, carrying out corrective maintenance, implementing preventive maintenance and minimizing machine downtime.

The primary objective is to maintain maximum machine availability with minimum breakdowns, minimum downtime and minimum maintenance cost, without compromising safety, quality or production requirements.

2. KEY RESPONSIBILITIESA. PLASTIC INJECTION MOULDING MACHINE MAINTENANCE

- Maintain all plastic injection moulding machines in proper working condition.
- Carry out preventive, predictive and breakdown maintenance of injection moulding machines.
- Understand the complete machine operating cycle and identify abnormalities at an early stage.
- Attend machine breakdowns immediately and restore production safely and systematically.
- Identify the root cause of repeated machine failures rather than repeatedly carrying out temporary repairs.
- Maintain machine availability and reduce unplanned downtime.
- Ensure critical spare parts are identified and maintained at appropriate stock levels.
- Maintain machine-wise maintenance history and breakdown records.
- Monitor recurring failures and implement permanent corrective actions.
- Coordinate with production personnel during machine breakdowns and planned maintenance activities.

3. PLC & CONTROL SYSTEM RESPONSIBILITIES

The Maintenance Engineer must possess solid practical knowledge of PLC-controlled injection moulding machines.

Responsibilities include:

- Diagnose PLC-related machine faults and alarms.
- Understand PLC inputs, outputs, sensors, actuators and machine interlocks.
- Troubleshoot PLC I/O-related problems.
- Identify faulty proximity sensors, limit switches, pressure switches, temperature sensors and other feedback devices.
- Diagnose communication faults between PLC, HMI, drives, controllers and other machine modules.
- Understand and troubleshoot HMI alarms and machine error messages.
- Check PLC input/output status during fault finding.
- Troubleshoot sequence-related problems and machine interlock issues.
- Check and rectify wiring, connectors, terminals and control-panel issues associated with PLC systems.
- Understand basic PLC program logic sufficiently for troubleshooting.
- Coordinate with machine OEM/service engineers for advanced PLC/software-related problems whenever required.
- Ensure PLC programs, parameters and machine data are properly backed up wherever applicable.
- Prevent unauthorized changes to PLC programs and machine parameters.

Expected capability: The engineer should be able to use the machine PLC/HMI information as a diagnostic tool and systematically trace a machine fault to its actual source.

4. ELECTRICAL MAINTENANCE

The engineer shall have strong practical knowledge of industrial electrical systems.

Responsibilities:

- Troubleshoot electrical breakdowns in injection moulding machines and auxiliaries.
- Diagnose problems in:
- MCC/control panels
- Contactors and relays
- MCB/MCCB
- Fuses
- SMPS
- Transformers
- Solenoid control circuits
- Motors
- Starters
- VFDs/AC drives
- Servo drives and servo motors
- Heaters and temperature-control circuits
- Sensors and switches
- Emergency-stop and safety circuits
- Check incoming electrical supply, phase condition, voltage and current.
- Identify loose connections, overheating terminals, cable failures and insulation-related problems.
- Troubleshoot motor-related problems.
- Carry out electrical panel inspection and preventive maintenance.
- Check heating zones, thermocouples, SSRs/contactors and temperature controllers.
- Ensure electrical panels are clean, properly ventilated and free from loose connections.
- Maintain proper earthing and electrical safety.
- Maintain electrical drawings and update records whenever modifications are made.

5. HYDRAULIC MAINTENANCE

The Maintenance Engineer shall possess strong practical knowledge of hydraulic systems used in injection moulding machines.

Responsibilities:

- Troubleshoot hydraulic system failures and pressure-related problems.
- Understand hydraulic circuits and identify the function of major hydraulic components.
- Maintain and troubleshoot:
- Hydraulic pumps
- Hydraulic motors
- Directional control valves
- Proportional/servo valves
- Pressure relief valves
- Solenoid valves
- Hydraulic cylinders
- Pressure sensors
- Flow-control valves
- Hydraulic filters
- Accumulators
- Oil coolers
- Hydraulic piping and hoses
- Diagnose abnormal hydraulic pressure, flow, temperature and response.
- Identify internal/external leakage and take corrective action.
- Monitor hydraulic oil condition and maintain appropriate oil levels.
- Ensure hydraulic filters are cleaned/replaced as per maintenance requirements.
- Check hydraulic hoses, fittings and pipelines for wear, leakage and damage.
- Prevent hydraulic contamination and overheating.




- Identify the root cause of repeated hydraulic failures.

6. MECHANICAL MAINTENANCE

The engineer shall have sound practical knowledge of mechanical systems associated with injection moulding machines.

Responsibilities:

- Troubleshoot mechanical failures in injection moulding machines and accessories.
- Inspect and maintain:
- Tie bars
- Toggle mechanisms
- Moving platen
- Fixed platen
- Injection unit
- Screw and barrel assembly
- Nozzle assembly
- Hydraulic/mechanical drive systems
- Motors
- Couplings
- Bearings
- Gearboxes
- Chains and sprockets
- Bushes
- Guide systems
- Lubrication systems
- Check abnormal noise, vibration, heating, wear and mechanical movement.
- Ensure proper lubrication of all applicable machine components.
- Check machine alignment and mechanical clearances.
- Attend mechanical abnormalities before they develop into major breakdowns.
- Ensure machine guarding and mechanical safety arrangements remain in proper condition.
- Support mould-setting and production teams during machine-related mechanical issues.

7. INJECTION MOULDING MACHINE ACCESSORIES

Maintain all auxiliary equipment associated with injection moulding operations, including, as applicable:

- Chillers
- Cooling towers
- Hot runners and temperature controllers
- Hopper dryers
- Dehumidifiers
- Auto loaders
- Material conveying systems
- Granulators
- Water circulation systems
- Oil coolers
- Thermic fluid systems
- Mould temperature controllers
- Air compressors
- Vacuum systems
- Conveyors
- Robots/automation systems
- Material handling and other machine auxiliaries

The engineer shall ensure that these accessories are maintained to prevent interruptions to production.

8. PREVENTIVE & PREDICTIVE MAINTENANCE

- Prepare and implement machine-wise preventive maintenance schedules.
- Ensure preventive maintenance is completed within the planned frequency.
- Follow OEM maintenance recommendations wherever applicable.
- Maintain daily, weekly, monthly, quarterly and annual maintenance activities.
- Inspect critical components before failure occurs.
- Monitor machine condition and identify early warning signs.
- Record all preventive maintenance activities.
- Analyze breakdown history and modify preventive-maintenance frequency where required.
- Ensure preventive maintenance does not become a mere checklist exercise; actual machine condition must be verified.
- Plan maintenance activities in coordination with Production to minimize production loss.

9. BREAKDOWN ANALYSIS & ROOT CAUSE

For every major or repeated breakdown:

- Attend the breakdown immediately.
- Safely isolate the machine.
- Identify the actual failure.
- Diagnose the root cause.
- Repair/replace the defective component.
- Test the machine thoroughly.
- Verify machine parameters and operation.
- Hand over the machine to Production only after confirming satisfactory operation.
- Record the breakdown and corrective action.
- Implement permanent corrective action to prevent recurrence.

Repeated temporary repairs without identifying the actual root cause shall be avoided.

10. MACHINE PARAMETER & QUALITY SUPPORT

- Understand the relationship between machine condition and moulding quality.
- Investigate machine-related causes of:
- Flash
- Short moulding
- Sink marks
- Burning
- Dimensional variation
- Warpage
- Weld-line problems
- Inconsistent filling
- Injection pressure variation
- Temperature variation
- Cycle-time variation
- Support Production and Quality departments during machine-related quality issues.
- Ensure critical machine parameters, sensors and control systems are functioning correctly.
- Prevent unauthorized or unnecessary changes to machine settings and control parameters.

11. MOULD & TOOL-RELATED SUPPORT

- Support Tool/Mould Maintenance and Production teams when machine-related conditions affect mould performance.
- Check machine platen, tie-bar, hydraulic and mechanical conditions that may contribute to mould damage.
- Verify machine/mould alignment and clamping-related conditions where applicable.
- Investigate machine-related causes of mould damage.
- Ensure abnormal machine movement, pressure or clamping conditions are attended immediately.

12. SAFETY RESPONSIBILITIES

- Follow electrical, mechanical, hydraulic and machine safety procedures at all times.
- Ensure proper isolation/LOTO before carrying out maintenance work where applicable.
- Never bypass safety interlocks, guards, emergency stops or other safety devices without authorized procedure and control.
- Ensure all maintenance work is carried out safely.
- Immediately report unsafe machine conditions.
- Maintain safety devices and emergency systems in working condition.
- Ensure maintenance tools and equipment are safe and properly maintained.

13. SPARES & MAINTENANCE COST CONTROL

- Identify critical machine spare parts.
- Maintain minimum/maximum stock levels for critical spares in coordination with Stores/Purchase.
- Avoid unnecessary replacement of components.




- Analyze whether components can be repaired or refurbished safely and economically.
- Control consumption of maintenance materials and spare parts.
- Maintain records of spare parts used for each machine.
- Monitor high-cost and frequently consumed spare parts.
- Recommend improvements to reduce recurring maintenance expenditure.

14. DOCUMENTATION & RECORDS

Maintain accurate and up-to-date:

- Machine-wise maintenance history
- Breakdown reports
- Preventive maintenance records
- Daily maintenance checklist
- Monthly PM records
- Spare-parts consumption records
- Machine downtime records
- Root Cause Analysis reports
- Corrective and Preventive Action records
- Electrical inspection records
- Hydraulic maintenance records
- Utility equipment maintenance records
- Machine parameter backup records, where applicable
- Maintenance-related IATF records/documents

All maintenance records shall be updated promptly and accurately.

15. 5S & SHOP-FLOOR DISCIPLINE

- Maintain excellent 5S standards in the Maintenance Department.
- Keep maintenance tools, spares, cables, lubricants and equipment properly arranged.
- Ensure oil, grease, hydraulic leaks and waste materials are immediately attended.
- Maintain clean and safe machine surroundings after every maintenance activity.
- Do not leave tools, dismantled parts, cables or scrap material on the shop floor.
- Follow company discipline, attendance and reporting requirements.
- Maintain proper communication with Production, Quality, Stores and Management.

16. BREAKDOWN RESPONSE & COMMUNICATION

- Respond immediately to production-critical machine breakdowns.
- Clearly communicate the expected repair status to Production.
- Escalate major or prolonged breakdowns to the Maintenance Head/Management.
- Inform management immediately when a breakdown may result in:
- Extended production stoppage
- Machine damage
- Mould damage
- Safety risk
- Major financial loss
- Customer delivery impact
- Do not allow a machine to remain stopped without proper escalation and action.

17. CONTINUOUS IMPROVEMENT

- Identify recurring machine problems and eliminate their root causes.
- Recommend machine modifications and improvements where beneficial.
- Reduce MTTR (Mean Time To Repair).
- Improve MTBF (Mean Time Between Failures).
- Reduce machine downtime.
- Improve machine reliability and availability.
- Identify opportunities for energy saving and maintenance-cost reduction.
- Support automation and machine improvement projects.
- Participate in TPM/continuous-improvement activities.

18. EXPECTED KEY PERFORMANCE INDICATORS (KPIs)

The Maintenance Engineer shall be evaluated based on:

- Machine availability
- Breakdown frequency
- Breakdown downtime
- MTBF improvement
- MTTR reduction
- Preventive maintenance completion %
- Repeat breakdown reduction
- Machine-related rejection reduction
- Mould/machine damage prevention
- Maintenance cost control
- Critical spare availability
- Response time to breakdowns
- Timely completion of maintenance activities
- Safety compliance
- 5S performance
- Accuracy and timely updating of maintenance records

19. QUALIFICATION

Preferred:

- Diploma / BE / B.Tech in Mechanical, Electrical, Electronics, Mechatronics or related engineering discipline.
- Relevant experience in plastic injection moulding machine maintenance is strongly preferred.

20. EXPERIENCE

Preferred Experience: 3–8 years in maintenance of plastic injection moulding machines and related industrial equipment.

Candidates with strong hands-on experience in injection moulding machine maintenance may be considered based on technical competency.

21. ESSENTIAL TECHNICAL SKILLS

The candidate should have hands-on troubleshooting capability in the following areas:

PLC / Automation

- PLC troubleshooting
- HMI
- Sensors
- I/O systems
- Machine interlocks
- Drives and servo systems
- Industrial control circuits

Electrical

- Control panels
- Motors
- VFDs
- Servo drives
- Heaters
- Temperature controllers
- Relays/contactors
- Electrical troubleshooting

Hydraulics

- Hydraulic pumps
- Valves
- Cylinders
- Pressure/flow systems
- Hydraulic circuits
- Leakage diagnosis
- Hydraulic filtration and cooling

Mechanical

- Injection unit
- Clamping unit
- Toggle mechanism
- Screw/barrel
- Bearings
- Gearboxes
- Couplings
- Lubrication
- Alignment and mechanical troubleshooting

22. PERSONAL ATTRIBUTES

The candidate should demonstrate:

- Strong hands-on technical ability
- Logical and systematic troubleshooting
- Ability to work under production pressure
- Quick response to breakdowns
- Strong sense of responsibility and ownership
- Good communication with Production and Quality teams
- Discipline and punctuality
- Problem-solving ability
- Cost-conscious approach
- Safety consciousness
- Willingness to work in shifts when required
- Ability to work independently without constant supervision

23. OVERALL ACCOUNTABILITY

The Maintenance Engineer is directly accountable for the reliability, availability and safe operating condition of the injection moulding machines and their accessories assigned to him.

He is expected to take proactive action rather than waiting for breakdowns to occur.

The primary responsibility is:

“PREVENT BREAKDOWNS – MINIMIZE DOWNTIME – PROTECT MACHINES & MOULDS – SUPPORT 100% QUALITY & ON-TIME PRODUCTION – CONTROL MAINTENANCE COST.”

Pay: ₹23,000.00 - ₹43,000.00 per month

Benefits:

- Health insurance
- Leave encashment

Work Location: In person

📌 Plastic Injection moulding Machine Maintenance Engineer (India)
🏢 Engineering Plastics, Mysore
📍 India