(JD)

Maintenance Engineer – Mechanical & Electrical

Department: Maintenance

Designation: Maintenance Engineer

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

Experience: 3–6 years in manufacturing industry (preferred)

Reporting To: Maintenance Head / Plant Head

Industry: Automotive Carpet / Non-Woven Manufacturing

1. Job Purpose

To ensure reliable, safe, and efficient operation of all production machinery and utility equipment by carrying out preventive maintenance, breakdown maintenance, troubleshooting, and continuous improvement activities for Needle Punch Lines, Press Moulding Lines, and associated mechanical and electrical systems.

2. Key Responsibilities

A. Mechanical Maintenance

1. Carry out preventive and breakdown maintenance of Needle Punch Lines and Press Moulding Lines.
2. Inspect and maintain bearings, gearboxes, motors, couplings, chains, sprockets, V-belts, timing belts, rollers, shafts, and pneumatic cylinders.
3. Inspect and maintain needle boards, needle looms, feed rollers, stripper plates, bed plates, conveyor systems, and other needle punch machine components.
4. Maintain hydraulic presses, hydraulic power packs, pumps, valves, cylinders, pipelines, and cooling systems.
5. Check hydraulic oil levels, oil leakage, pressure, filters, lubrication systems, and grease points.
6. Identify abnormal noise, vibration, overheating, and mechanical misalignment.
7. Carry out alignment, fitting, assembly, dismantling, and replacement of mechanical components.
8. Coordinate with OEMs and external service providers for major repairs and machine overhauling.

B. Electrical Maintenance

1. Carry out electrical troubleshooting and maintenance of motors, control panels, MCC panels, distribution panels, and machine wiring.
2. Troubleshoot PLC, HMI, VFD/inverter, servo drive, sensors, limit switches, proximity sensors, encoders, and safety interlocks.
3. Inspect and maintain electrical connections, contactors, relays, MCBs, MCCBs, overload relays, and control circuits.
4. Check motor current, voltage, insulation resistance, earthing, and electrical connection tightness.
5. Diagnose electrical faults in needle punch machines, press moulding machines, heating systems, and conveyor drives.
6. Maintain electrical and temperature control systems, including heaters, thermocouples, temperature controllers, and associated protection devices.
7. Ensure proper functioning of emergency stop circuits, machine guards, safety switches, and electrical protection systems.
8. Assist in installation, commissioning, electrical modifications, and machine relocation activities.

C. Hydraulic and Pneumatic Systems

1.



Troubleshoot hydraulic and pneumatic systems used in press moulding and needle punch machinery.
2. Monitor hydraulic pressure, oil temperature, filter condition, air pressure, FRL units, solenoid valves, and pneumatic actuators.
3. Identify and rectify hydraulic oil leakage, air leakage, pressure drops, and abnormal system operation.
4. Ensure proper operation of hydraulic cooling systems, pumps, and power packs.

D. Preventive and Predictive Maintenance

1. Prepare and implement daily, weekly, monthly, quarterly, and annual preventive maintenance schedules.
2. Maintain machine-wise maintenance checklists and equipment history records.
3. Monitor breakdown frequency, machine availability, MTTR, and MTBF.
4. Conduct inspections for abnormal vibration, noise, temperature, lubrication, and wear.
5. Plan critical spare parts requirements and maintain minimum stock levels.
6. Analyse repeated breakdowns and implement root cause analysis (RCA) and corrective/preventive actions.
7. Ensure timely completion of maintenance activities to minimise production downtime.

E. Utility Maintenance

1. Support maintenance of air compressors, dryers, pumps, cooling towers, chillers, and other plant utilities, as applicable.
2. Monitor utility operating parameters and carry out scheduled servicing.
3. Inspect utility pipelines, electrical connections, leakage, and safety protection systems.
4. Coordinate with utility equipment suppliers for servicing and technical support.

F. Safety and Compliance

1. Follow applicable electrical and mechanical safety procedures during maintenance activities.
2. Ensure implementation of Lockout/Tagout (LOTO) before maintenance work.
3. Use appropriate PPE and ensure safe working practices.
4. Ensure machine guards and safety interlocks are functional before releasing equipment for production.
5. Maintain housekeeping and follow 5S practices in the maintenance workshop and machine areas.
6. Support statutory inspections, electrical safety checks, and equipment safety audits as applicable.

G. Documentation and Reporting

1. Maintain preventive maintenance records, breakdown reports, spare consumption records, and equipment history.
2. Prepare daily maintenance activity reports and monthly maintenance performance reports.
3. Maintain records of machine modifications, electrical drawings, mechanical drawings,



and PLC backups where applicable.
4. Coordinate with Production, Quality, Stores, Purchase, and external vendors.
5. Prepare technical specifications and support spare parts identification, quotations, and purchase requests.

3. Technical Knowledge Required

- Mechanical drives, bearings, gearboxes, lubrication, alignment, and power transmission systems.
- Needle punch machinery and associated feeding, needling, and conveying mechanisms.
- Hydraulic press systems, hydraulic power packs, pumps, valves, and cylinders.
- Industrial electrical systems, motors, starters, MCC panels, and control circuits.
- PLC, HMI, VFD, sensors, and industrial automation troubleshooting.
- Hydraulic, pneumatic, and temperature control systems.
- Electrical safety, earthing, insulation testing, and preventive maintenance.
- Basic knowledge of technical drawings, electrical schematics, and machine manuals.
- MS Excel and maintenance reporting systems.

4. Required Skills

- Strong mechanical and electrical troubleshooting skills.
- Ability to analyse machine breakdowns and identify root causes.
- Preventive maintenance planning and execution.
- Effective coordination with Production and other departments.
- Ability to manage maintenance activities during production shifts.
- Technical communication, documentation, and reporting skills.
- Teamwork, discipline, ownership, and problem-solving ability.

5. Key Performance Indicators (KPIs)

1. Reduction in machine breakdowns and production downtime.
2. Achievement of preventive maintenance schedule compliance.
3. Improvement in machine availability and reliability.
4. Reduction in repeat breakdowns.
5. Timely completion of corrective maintenance.
6. Control of maintenance spare parts and repair costs.
7. Compliance with machine safety and electrical safety requirements.
8. Accuracy and timely completion of maintenance records.

6. Authority and Responsibility

- Execute approved preventive and corrective maintenance activities.
- Identify unsafe machine conditions and recommend immediate corrective action.
- Coordinate with production personnel for planned maintenance and breakdown rectification.
- Recommend spare parts, repairs, and machine improvements to the Maintenance Head.
- Ensure machinery is handed back to Production only after the required safety and functional checks.

7. Working Conditions

- Manufacturing plant setting.
- May be required to attend emergency breakdowns and work in shifts, depending on plant requirements.
- Must follow all plant safety procedures and work permit requirements.

Pay: ₹10,000.00 - ₹49,000.00 per month

Work Location: In person

📌 Maintenance (Jalisana)
🏢 HITKARI HITECH PRIVATE
📍 Jalisana