Senior Engineer – Maintenance (Injection Moulding)

Department: Maintenance / Engineering

Designation: Senior Engineer – Maintenance

Industry: Plastic Injection Moulding / Automotive / Manufacturing

Experience: 5–8 years

Qualification: Diploma / B.E. / B.Tech in Mechanical, Electrical, or Mechatronics Engineering

Reporting To: Maintenance Manager / Plant Head

Location: As per company requirements

1. Job Purpose To ensure maximum uptime, reliability, and efficient operation of injection moulding machines, auxiliary equipment, utilities, and plant infrastructure through preventive, predictive, and breakdown maintenance activities.

2. Key Responsibilities

A. Injection Moulding Machine Maintenance

- Handle maintenance of hydraulic, all-electric, and servo-hydraulic injection moulding machines.
- Troubleshoot hydraulic, pneumatic, electrical, mechanical, and control system failures.
- Diagnose faults in PLCs, servo drives, VFDs, sensors, contactors, relays, heaters, thermocouples, and temperature controllers.
- Maintain injection units, clamping units, toggle mechanisms, hydraulic pumps, valves, cylinders, and lubrication systems.
- Ensure proper functioning of safety interlocks, emergency stops, guards, and machine protection systems.
- Coordinate with OEM service engineers for major repairs and technical support.

B. Preventive and Predictive Maintenance

- Prepare and execute preventive maintenance schedules for machines and auxiliary equipment.
- Conduct routine inspections, condition monitoring, and equipment health checks.
- Monitor recurring breakdowns and implement permanent corrective actions.
- Maintain machine history cards, maintenance checklists, and equipment records.
- Implement TPM, 5S, and reliability improvement activities.

C. Auxiliary Equipment and Utilities

- Maintain and troubleshoot:
- Chillers and cooling tower systems
- Mould temperature controllers (MTC)
- Hopper dryers, dehumidifiers, and material loaders
- Granulators and material conveying systems




- Air compressors and pneumatic systems
- Pumps, motors, gearboxes, and electrical panels
- Ensure reliable cooling water, compressed air, and other utility supplies to production equipment.

D. Breakdown Management and Production Support

- Attend machine breakdowns promptly and minimize production downtime.
- Coordinate with production, quality, and tooling teams to resolve equipment-related issues.
- Analyze breakdown data and perform Root Cause Analysis (RCA).
- Implement corrective and preventive actions to avoid repeat failures.
- Support machine installation, commissioning, shifting, and capacity expansion.

E. Spare Parts and Documentation

- Maintain critical spare parts inventory and minimum stock levels.
- Identify spare parts requirements and coordinate with purchase and stores departments.
- Maintain maintenance logs, breakdown reports, MTTR, MTBF, and preventive maintenance compliance records.
- Prepare daily, weekly, and monthly maintenance performance reports.

F. Safety and Compliance

- Ensure compliance with electrical safety, machine safety, LOTO, and permit-to-work procedures.
- Ensure all maintenance work is performed according to safety standards.
- Support statutory inspections, safety audits, and internal quality audits.
- Maintain housekeeping and safe working conditions in the maintenance area.

G. Team Management and Improvement

- Guide technicians and maintenance staff in troubleshooting and repair activities.
- Coordinate shift-wise maintenance activities and breakdown support.
- Train operators and technicians in basic equipment care and autonomous maintenance.




- Identify opportunities to reduce energy consumption, maintenance costs, and unplanned downtime.
- Support continuous improvement, Kaizen, and productivity enhancement projects.

3. Required Technical Skills

- Strong knowledge of injection moulding machine maintenance.
- Practical experience with hydraulic, pneumatic, electrical, and mechanical systems.
- Knowledge of PLCs, HMI, servo motors, drives, sensors, and industrial automation.
- Understanding of injection moulding machine operating principles and safety systems.
- Experience in preventive maintenance, breakdown maintenance, and troubleshooting.
- Knowledge of chillers, dryers, compressors, MTCs, and other auxiliary equipment.
- Familiarity with RCA, 5 Why, Fishbone Analysis, TPM, 5S, MTTR, and MTBF.
- Working knowledge of MS Excel and maintenance management systems.

4. Key Performance Indicators (KPIs)

- Machine availability and uptime
- Reduction in unplanned breakdowns
- Preventive maintenance compliance
- Reduction in MTTR and improvement in MTBF
- Maintenance cost per machine
- Spare parts inventory control
- Repeat breakdown reduction
- Compliance with safety and housekeeping standards

5. Desired Candidate Profile

- Hands-on experience in injection moulding machine maintenance.
- Ability to independently troubleshoot mechanical, hydraulic, electrical, and automation-related faults.
- Good analytical, problem-solving, and decision-making skills.
- Ability to work in rotational shifts and support urgent breakdowns, as required.
- Solid coordination skills with production, quality, tooling, and utility teams.
- A proactive approach to equipment reliability, safety, and continuous improvement.

Pay: ₹35,000.00 - ₹86,000.00 per month

Benefits

- Cell phone reimbursement
- Commuter assistance
- Flexible schedule
- Food provided
- Paid sick time
- Paid time off
- Provident Fund

Work Location: In person

📌 Senior Engineer - Maintenance (Injection Moulding) (Imt Manesar)
🏢 Krishna Penstone Automotive
📍 Imt Manesar