FOR SR. MAINTENANCE ENGINEER CUM INCHARGE

1. POSITION DETAILS

Designation: Sr. Maintenance Engineer Cum Incharge

Department: Maintenance

Reporting To: Plant Head / Factory Head / Management

Location: Chhapi joining date:

Mo:

Notice Period: 45 Days with Proper Charge Handover email :

2. JOB PURPOSE The Sr. Maintenance Engineer Cum Incharge will be fully responsible for overall plant maintenance management, machine reliability, breakdown control, preventive maintenance, manpower management, maintenance planning, cost control, safety, documentation, reporting and continuous improvement.

The person shall establish a systematic maintenance structure covering all machines, overhead cranes, hydraulic power packs, welding machines, utilities and other maintenance-related equipment and shall ensure maximum equipment availability with minimum breakdown, minimum maintenance cost and optimum utilization of manpower.

The position requires strong technical knowledge, leadership, planning, reporting, accountability, troubleshooting and decision-making ability.

1. FIRST 30 DAYS MANDATORY PLANT & MAINTENANCE ASSESSMENT

Within the first one month of joining, the employee shall conduct a complete technical and operational assessment of the plant. A. Complete Machine Survey

Prepare a detailed database of all available machines/equipment in the plant, including:

- Machine Name
- Machine ID / Tag No.
- Manufacturer
- Model
- Machine Capacity
- Year of Installation
- Electrical Details
- Motor Details
- Hydraulic/Pneumatic Details
- Major Components
- Current Condition
- Current Working Status
- Last Maintenance Date
- Previous Breakdown History
- Pending Maintenance
- Critical Spare Requirements
- Maintenance Frequency
- Estimated Replacement Cost
- Recommended Action

A proper Machine Master Data Sheet shall be prepared for every machine.

1. MACHINE TAGGING & IDENTIFICATION SYSTEM

Every machine shall have a proper Machine Identification Tag. The tag/data sheet should allow any authorized person to immediately understand:
- Machine Name
- Machine ID
- Capacity
- Major Technical Details
- Maintenance Frequency
- Last Maintenance Date
- Next Maintenance Due Date
- Current Status
- Critical Spare Details
- Responsible Maintenance Person

The objective is to establish a Machine History & Traceability System.

1. BREAKDOWN STATUS & ANALYSIS

Prepare a complete report of all existing and pending breakdowns.

The report shall include

- Machine-wise Breakdown Status
- Breakdown Date & Time
- Nature of Breakdown
- Root Cause
- Repair Status
- Material/Spare Required
- Material Availability
- Outside Repair Status
- Expected Completion Date
- Responsible Person
- Actual Downtime
- Production Loss, wherever applicable
- Corrective Action
- Preventive Action

The employee shall develop a system to reduce repetitive breakdowns and identify Root Causes.

1. MAINTENANCE MATERIAL / OUTSIDE REPAIR STATUS

Prepare a detailed status report of all items currently sent or pending for maintenance/repair outside the plant.

The report should include

- Item/Machine Name
- Component Name
- Vendor/Repair Agency
- Date Sent
- Reason for Repair
- Repair Status
- Expected Return Date
- Estimated Repair Cost
- Actual Repair Cost
- Replacement Cost
- Responsible Person
- Pending Action

Continuous follow-up shall be maintained until the repaired item is received, inspected and commissioned.
1. MANPOWER ASSESSMENT – INTERVIEW & PERFORMANCE REVIEW

Within the initial assessment period, the Sr. Maintenance Engineer shall personally interact/interview each existing maintenance employee. A manpower database shall be prepared containing:
- Employee Name
- Designation
- Qualification
- Technical Skills
- Experience
- Machine Knowledge
- Electrical/Mechanical/Hydraulic/Pneumatic Knowledge
- Troubleshooting Ability
- Safety Awareness
- Shift Capability
- Attendance & Regularity
- Responsibility Level
- Present Job Performance
- Strengths
- Weaknesses
- Training Requirements
- Suitable Job Responsibility
- Recommended Improvement Plan

1. MANPOWER PERFORMANCE VS. SALARY EVALUATION

The employee shall evaluate whether the existing manpower is delivering work as expected against their:
- Designation
- Salary Level
- Experience
- Assigned Responsibility
- Technical Capability
- Productivity
- Accountability

Where a performance gap / skill gap / responsibility gap is identified, prepare a proper management report with recommended corrective action. The report must be factual, professional and based on actual work performance.

9. NEW MANPOWER / REPLACEMENT RECOMMENDATION

Where existing manpower is insufficient, unsuitable or lacks required technical capability, prepare a Manpower Requirement & Replacement Proposal.

The employee shall use his/her professional industry experience and legitimate professional network to identify potential candidates where appropriate.

The recommendation should include

- Required Position
- Required Qualification
- Required Experience
- Required Technical Skills
- Expected Salary Range
- Reason for Requirement
- Existing Manpower Gap
- Replacement/Additional Manpower Requirement
- Candidate Options, where available
- Recommended Candidate

Final recruitment shall remain subject to Management approval.
1. OVERHEAD CRANE – COMPLETE DATA MANAGEMENT

Prepare a complete database of all Overhead Cranes / EOT Cranes / Material Handling Equipment.

The report should include

- Crane ID
- Capacity
- Manufacturer
- Installation Year
- Hoist Details
- Motor Details
- Brake Details
- Rope/Chain Details
- Control Panel Details
- Limit Switch Details
- Pendant/Remote Details
- Current Condition
- Last Maintenance
- Breakdown History
- Preventive Maintenance Schedule
- Safety Inspection Status
- Pending Repair
- Critical Spare Requirements

All crane maintenance shall be carried out with proper safety precautions and applicable statutory/company requirements.
1. HYDRAULIC POWER PACK DATABASE

Prepare a complete list of all Hydraulic Power Packs installed/available in the plant.

Clearly identify

- Location
- Machine Connected
- Power Pack Capacity
- Motor Details
- Pump Details
- Current Status
- Working / Standby / Breakdown
- Maintenance Status
- Oil Condition
- Filter Status
- Major Component Condition
- Spare Requirement

Special attention shall be given to extra/standby hydraulic power packs and their actual availability.

1.



WELDING MACHINE DATABASE

Prepare a complete database of all welding machines available in the plant.

The report shall include

- Machine ID
- Welding Process
- Make
- Model
- Capacity
- Current Rating
- Location
- User Department
- Working Status
- Breakdown Status
- Last Maintenance Date
- Calibration/Inspection Status, where applicable
- Cable/Holder/Gun Condition
- Repair Requirement
- Spare Requirement
- Replacement Recommendation

A Current Welding Machine Status Report shall be maintained and periodically updated.

1. COMPLETE PLANT MAINTENANCE CONDITION REPORT

After completing the initial survey, prepare a comprehensive Plant Maintenance Current Situation Report covering:

Equipment

- Total Machines
- Working Machines
- Breakdown Machines
- Critical Machines
- Old Machines
- Machines Requiring Major Repair
- Machines Recommended for Replacement

Maintenance

- Pending Preventive Maintenance
- Pending Breakdown Maintenance
- Major Repair Jobs
- Outside Repair Jobs
- Critical Spare Requirements

Manpower

- Existing Manpower
- Skill-wise Manpower
- Shift-wise Manpower
- Manpower Shortage
- Training Requirements
- Recruitment Requirements

Cost

- Current Maintenance Cost
- Repair Cost
- Spare Cost
- Outside Repair Cost
- Repeated Breakdown Cost
- Old Machine Maintenance Cost
- Replacement Cost

1. MAINTENANCE SOP DEVELOPMENT

Develop and implement a proper Maintenance SOP System covering:
- Preventive Maintenance
- Breakdown Maintenance
- Predictive/Condition-Based Maintenance, wherever practical
- Emergency Breakdown Procedure
- Machine Inspection
- Lubrication
- Electrical Maintenance
- Mechanical Maintenance
- Hydraulic Maintenance
- Pneumatic Maintenance
- Welding Equipment Maintenance
- Crane Maintenance
- Outside Repair Procedure
- Spare Management
- Maintenance Documentation
- Safety Procedure
- Shift Handover Procedure

1. PREVENTIVE MAINTENANCE SYSTEM

Establish a structured Preventive Maintenance Calendar based on:
- Daily Maintenance
- Weekly Maintenance
- Monthly Maintenance
- Quarterly Maintenance
- Half-Yearly Maintenance
- Annual Maintenance

Preventive Maintenance records must clearly show: Planned Date Actual Date Work Done Parts Used Findings Responsible Person Next Due Date

1. BREAKDOWN REDUCTION & ROOT CAUSE ANALYSIS

The employee shall focus on reducing:
- Repeated Breakdowns
- Unplanned Downtime
- Machine Failure
- Emergency Repairs
- Production Interruption

For major/repetitive breakdowns, perform Root Cause Analysis (RCA) and implement corrective/preventive actions. Where appropriate, use:

- 5 Why Analysis
- Fishbone Analysis
- Failure History
- Component Life Analysis

1. OLD MACHINE & REPLACEMENT ANALYSIS

Prepare an Old Machine Cost & Replacement Recommendation Report.

Compare

Annual Repair & Maintenance Cost + Downtime Cost + Spare Cost + Outside Repair Cost against

New Machine Purchase / Replacement Cost

Based on technical and financial evaluation, recommend whether the machine should be:

- Continued
- Repaired
- Overhauled
- Upgraded
- Replaced

Final replacement decisions shall be taken by Management.
1. MAINTENANCE COST CUTTING

Identify opportunities for legitimate and sustainable maintenance cost reduction through:
- Breakdown Reduction
- Preventive Maintenance
- Better Spare Planning
- Vendor Negotiation
- In-house Repair
- Reduction of Repeated Repairs
- Proper Lubrication
- Energy Efficiency
- Better Component Life
- Proper Material Usage
- Repair vs. Replacement Analysis
- Reduction of Emergency Purchases

Cost cutting shall not compromise machine safety, statutory compliance, product quality or employee safety.

1. SHIFT DUTY & MANPOWER PLANNING

Prepare and manage shift-wise maintenance manpower planning.

Responsibilities include

- Shift Duty Roster
- Machine Coverage
- Emergency Coverage
- Skill-wise Deployment
- Leave Replacement
- Shift Handover
- Work Allocation
- Technician Productivity
- Overtime Control

Ensure that critical machines receive appropriate maintenance coverage. 20. SAFETY & MAINTENANCE TRAINING

Conduct regular technical and safety training for maintenance personnel covering:

- Electrical Safety
- LOTO – Lockout/Tagout
- Working at Height
- Crane Safety
- Hydraulic Pressure Safety
- Pneumatic Safety
- Welding Equipment Safety
- PPE
- Fire Safety
- Emergency Breakdown Safety
- Safe Use of Tools
- Machine Isolation
- Preventive Maintenance Safety

No maintenance work shall be carried out by bypassing required safety procedures. 21. OVERTIME CONTROL – ZERO OVERTIME APPROACH

Develop an effective manpower and maintenance planning system with the objective of maintaining Zero / Minimum Avoidable Overtime.

Overtime, where unavoidable due to genuine emergency breakdowns or business requirements, shall be properly justified, documented and approved as per company policy.

22. DAILY MAINTENANCE WORK REPORT A Daily Maintenance Report shall be prepared containing:

- Date
- Shift
- Machine
- Complaint
- Breakdown Time
- Work Started
- Work Completed
- Parts Used
- Pending Work
- Downtime
- Root Cause
- Corrective Action
- Responsible Technician
- Supervisor/Engineer
- Production Impact
- Next Action

1. DAILY MORNING MEETING

Conduct/participate in a daily morning maintenance meeting covering:
- Previous Day Breakdown
- Pending Jobs
- Today's Planned Maintenance
- Preventive Maintenance
- Critical Machines
- Spare Availability
- Manpower Availability
- Outside Repair Status
- Safety Concerns
- Production Requirements
- Priority Jobs

Explicit work allocation and responsibility shall be assigned to each concerned person.
1. EVENING REVIEW MEETING

Conduct an evening review to evaluate:
- Completed Jobs
- Pending Jobs
- Breakdown Status
- Preventive Maintenance Status
- Critical Machine Status
- Material/Spare Pending
- Outside Repair Pending
- Manpower Issues
- Safety Issues
- Next Shift Requirements

All pending jobs must have a clear responsible person and target completion date.

1. RESPONSIBILITY & ACCOUNTABILITY

The Sr.



Maintenance Engineer Cum Incharge shall ensure that every maintenance activity has: Job Responsible Person Target Date Status Verification Closure

“Pending” work without ownership or follow-up shall not be acceptable.

The employee shall establish a culture of Responsibility, Accountability, Discipline and Timely Completion.

26. DOCUMENTATION & RECORD CONTROL

Maintain and regularly update

- Machine Master List
- Machine History Card
- Preventive Maintenance Schedule
- Breakdown Register
- Spare Parts Register
- Outside Repair Register
- Crane Maintenance Register
- Welding Machine Register
- Hydraulic Power Pack Register
- Daily Maintenance Report
- Shift Handover Report
- Maintenance Cost Report
- Manpower Skill Matrix
- Training Records
- Old Machine Replacement Report
- Critical Spare List
- Maintenance KPI Report

1. KPI MANAGEMENT

The employee shall establish and monitor maintenance KPIs such as:
- Machine Availability %
- Breakdown Hours
- Breakdown Frequency
- MTBF – Mean Time Between Failures
- MTTR – Mean Time To Repair
- Preventive Maintenance Compliance %
- Repeat Breakdown %
- Maintenance Cost
- Spare Consumption
- Outside Repair Cost
- Overtime Hours
- Machine Downtime
- Critical Machine Availability
- Maintenance Job Closure %
- Safety Compliance

28. MANAGEMENT REPORTING Submit regular reports to Management / Plant Head covering:

Daily

- Breakdown Report
- Maintenance Work Report
- Critical Pending Jobs

Weekly

- Preventive Maintenance Status
- Breakdown Analysis
- Spare Requirement
- Outside Repair Status
- Manpower Status

Monthly

- Maintenance KPI
- Maintenance Cost
- Breakdown Trend
- Machine Health
- Old Machine Status
- Replacement Recommendations
- Manpower Requirement
- Cost Reduction Achievements
- Improvement Projects

1. VENDOR & OUTSIDE REPAIR MANAGEMENT

Manage maintenance-related vendors and outside repair agencies.

Responsibilities include

- Technical Requirement
- Repair Enquiry
- Vendor Evaluation
- Technical Discussion
- Repair Follow-up
- Delivery Follow-up
- Quality Verification
- Cost Comparison
- Repair vs. Replacement Evaluation

All major commercial decisions shall remain subject to company approval procedures.
1. CONTINUOUS IMPROVEMENT

Identify opportunities for improvement in:
- Machine Reliability
- Maintenance Process
- Manpower Productivity
- Spare Consumption
- Maintenance Cost
- Breakdown Reduction
- Machine Life
- Safety
- Documentation
- Work Planning
- Response Time

The employee shall continuously develop systems rather than depending only on reactive breakdown maintenance.
1. REQUIRED TECHNICAL COMPETENCIES

The candidate should have strong knowledge of:
- Mechanical Maintenance
- Electrical Maintenance
- Hydraulic Systems
- Pneumatic Systems
- Motors
- Gearboxes
- Pumps
- Bearings
- Valves
- Welding Machines
- EOT/Overhead Cranes
- Hydraulic Power Packs
- Industrial Equipment
- Preventive Maintenance
- Breakdown Troubleshooting
- Root Cause Analysis
- Maintenance Planning
- Spare Management
- Technical Documentation

Knowledge of relevant industrial safety practices, statutory requirements and applicable standards will be an advantage. 32. REQUIRED MANAGEMENT SKILLS

- Leadership
- Team Management
- Manpower Planning
- Shift Management
- Problem Solving
- Decision Making
- Vendor Management
- Cost Control
- Reporting
- Documentation
- Communication
- Time Management
- Discipline
- Accountability
- Technical Training
- Continuous Improvement

33. EMPLOYEE CONDUCT & COMPANY DISCIPLINE The employee shall:

- Maintain regular attendance and punctuality.
- Follow all company rules and regulations.
- Maintain professional conduct.
- Maintain confidentiality of company technical and commercial information.
- Follow safety procedures strictly.
- Properly maintain company records.
- Not neglect assigned responsibilities.
- Ensure proper communication during shift changes.
- Escalate critical technical/safety issues to Management immediately.
- Take proper ownership of assigned maintenance responsibilities.

34. ONE-YEAR STABILITY REQUIREMENT Considering the technical responsibility, plant assessment, system development and training investment associated with this position, the employee is expected to maintain a minimum employment stability of one year.

The employee should not leave the organization without proper completion/transfer of assigned responsibilities and projects.

35. 45-DAY NOTICE & PROPER CHARGE HANDOVER In case of resignation, the employee shall provide a minimum 45 days' notice, subject to company policy and employment terms.

Before relieving, the employee must complete a proper Charge Handover covering:

- Machine Master Data
- Machine History
- Pending Breakdown
- Preventive Maintenance
- Critical Spare Status
- Outside Repair Status
- Vendor Details
- Manpower/Duty Planning
- Maintenance Schedule
- Ongoing Projects
- Pending Purchase/Repair Requirements
- Critical Machine Issues
- Documents and Registers
- Passwords/access credentials, where applicable and permitted
- Any other pending responsibility

Final relieving shall be subject to satisfactory handover and applicable company policy/contract terms. 36. KEY EXPECTATION FROM THE POSITION The Sr. Maintenance Engineer Cum Incharge is expected to transform the Maintenance Department from a reactive breakdown-based system into a planned, documented, accountable and preventive maintenance system.

PRIMARY OBJECTIVES:

- Maximum Machine Availability.
- Minimum Breakdown.
- Minimum Downtime.
- Minimum Avoidable Overtime.
- Optimum Manpower Utilization
- Minimum Maintenance Cost.
- Proper Preventive Maintenance.
- Complete Machine Documentation.
- Strong Safety Culture.
- Clear Responsibility & Accountability.
- Timely Reporting & Job Closure.
- Continuous Improvement.

MANAGEMENT EXPECTATION The person appointed for this position shall not work only as a breakdown technician/engineer. He shall function as the overall Maintenance System Owner, responsible for establishing, implementing, monitoring and continuously improving the complete maintenance system of the plant. The employee shall be capable of independently identifying problems, preparing data-based reports, proposing solutions, managing manpower, controlling maintenance costs and presenting clear recommendations to Management.

All responsibilities are subject to company policies, applicable laws, statutory requirements, safety requirements and Management approval wherever applicable.

📌 Maintenance Incharge (Palanpur)
🏢 VASANT FABRICATORS
📍 Palanpur