Job Profile :                

 

Level                : L3

Designation    : Asst. Mgr. / Manager (Planned Maintenance) Electronics (MCD)

Qualification : Graduate in Electronics Engg. from reputed institute 

   (with good academic track records)

Experience      : Between 3 to 5 years, preferably in Automobile / Engineering Industry

Location         : Bajaj Auto Ltd, Waluj – Aurangabad (Maharashtra) – Motorcycle plant

Age                  : Around 27 years

 

 

Brief job Description:

Breakdown Maintenance:

1. To Achieve & Sustain Zero breakdown & Zero minor stoppages in Plant i.e. Machine shop, paint shop and Assembly line equipment’s like CNC, HMC, VMC, SPMS, honing, PLC automations, pick & place Robots, assembly conveyor line, Pneumatic nut runners, DC tools, LCA automations.
2. Guide and support team members for quick restoration of daily equipment failures. Do kaizens for reducing MTTR.
3. Analysis of each failure using tools like why-why analysis, root cause failure analysis, Fault tree analysis, FMEA and take immediate restoration actions & countermeasure corrective action to Increase MTBF.
4. Execute various AMCs for Maintenance activities and PM of precision equipment’s like CMM, tool presetters, DC tools, surface testers, PNR and Auxiliary equipment’s like Trollies, chillers, etc. Co-ordinate with Vendors & central team for systematic execution.
5. Planning & implementation of activities for Zero failures in Electronics systems like- FANUC servo drives, siemens LT modules, 24V SMPS, Various CNC control PCBs, etc.

 

Preventive Maintenance:

1. To Carryout planned maintenance activities as per yearly/monthly/daily planning of various equipment’s like CNC machines, HMC, VMC, Honing, ABB Robots, SCARA, PLC automations, Hydraulic & pneumatic Press machines, washing machines, Line conveyors slat, Power & free, DC tools, ARPs, vehicle testing equipment’s, etc.
2. To Improve & sustain Preventive Maintenance system of Machine shop & assembly line shop by doing various kaizens related to MTBPM (part life enhancement) & MTTPM (PM activity time reduction).
3. Regularly revisit & update documents for changes in PM plan, shop equipment’s, PM check sheets, etc.
4. Co-ordinate with vendors & central team for execution of AMCs for preventive maintenance & annual calibration of applicable equipment.
5. Daily/Weekly review of PM system through PM board for sustenance & improvement planning.
6. Daily use of CMMS system for PM data update & monitoring.

 

 

 

Predictive maintenance:

1. To carry out CBM activities as per plan. Develop new CBM tools & techniques to enhance the CBM efficiency. do kaizens based on CBM data monitoring & analysis.

 

Budget & Spares Planning & procurement:

1. Planning of fixed cost & spares budget for machine shop & assembly lines
2. Planning of Spares required for general consumables, RBM, CBM, TBM & Insurance spares & regular procurement as per requirement.
3. Machine / line wise spare parts list & spares replacement history.

 

             Systems & updates:

1. Daily use of CMMS system for PM system compliance: 1. Breakdown entry & Why-why analysis 2. PM compliance 3. Equipment masters 4. PM plan 5. Inventory management, etc.
2. Use of SAP system for Procurement of spares & Spares management.
3. MP information system (Maintenance prevention)

 

              Implementation of activities:

1. Corrective maintenance (CM), Reliability centered Maintenance (RCM), Life cycle cost analysis (LCCA) Artificial intelligence (AI), Online machine health monitoring Systems, etc.
2. Initiate upgradation, reconditioning and modifications in machine & line equipment.

 

Improvement activities based on:

1. happened BD cases 2. in-process defects 3. internal customer complaints 4. Safety requirements 5. Quality requirements- error proofing on assembly lines
2.  Support to JH team for zero abnormalities sustenance & digitization of JH activities on machines & assembly lines

 

To initiate cost saving proposals for:

1. Maintenance cost saving through alternate source, inhouse development, import substitutes, etc.
2. Energy – Daily Shop energy monitoring & plan for energy consumption reduction through new initiatives, technological upgradations, etc.

 

Adapt to new technology & trends –

Plan for adaption of new technology changes in Industry 4.0 & IOT, smart manufacturing, automatons, AI, Vision technology, etc.

 

Guide team members on daily issues and get the work done from them more effectively.

 

Effective communication with the people down the level and people at higher level.

 

 

 

Exposure / Experience in the following area:

1. Should have experience of working on various CNC machines like Mazak, NTC, FRD, AMS, Brother, Gehring & SPMs like Hydraulic & Pneumatic press, Washing machines, boring machines, Robots like FANUC, ABB, Mitsubishi SCARA.
2. Working on various Assembly line conveyors like slat, power & free, PLC automations, Robotic automations, Dynameters, SCARA & cobots, IR, Atlas Copco & Diachi DC tools & Pneumatic nut runners., special assembly tools & tackles. Vison systems.

 

3. Should have good knowledge of PMC programming & Maintenance of 

1. FANUC   CNC controllers - Oi,16i,18i,31i MA
2. SIEMENS   CNC controllers – 810D,840D, 840DSL
3. Robot controllers – ABB Pick & place, Fanuc, Mitsubishi SCARA

 

4. Should have good knowledge

1. PLC programming & Maintenance of PLC controllers: Mitsubishi FX /Q series, Siemens S7-300, Messung 5K, ABB, Siemens VIPA.
2. Servo drives: FANUC, Siemens, ABB, Mitsubishi
3. VFD systems: Mitsubishi, Danfoss, siemens, ABB.

 

5. Should be able to upload / download SRAM Backup, Programs, Parameters, Ladder from CNC & PLCs.
6. Should be able to work on PC based systems with HDDs.
7. Should have exposure in Mechatronics – knows basics of sensors, actuators, pneumatics, hydraulics used in Mechanical systems, calibration of systems.

 

8. Experience on machine PLC logic development independently.

 

9. Experience on use of Assembly line systems:

1. Pokayoke system & development of new pokayoke for error proofing.
2. ANDON system for assembly stoppages monitoring

 

10. Experience on executing AMC of critical machine maintenance & calibration activities.

 

11. Should have knowledge and exposure in implementation of TPM systems in assembly & Machine shop, including JH activities, PM activities - TBM / CBM, MTTR/MTBF etc.

                    And knows about kaizen, Pokayoke, Karakuri, 5S, etc.

 

12. In-depth knowledge about PM concepts like Why-Why analysis, root cause analysis, fault tree analysis, FMEA, implementation of corrective actions on various equipment assembly machine shops

 

13. Understanding of Maintenance requirement: Preventive maintenance – IR, TBM,

                    Predictive maintenance CBM, Corrective Maintenance Engineering Kaizens.

 

 

14. Experience on Planning & execution of PM activities as per plan.

 

15. Upkeep of Maintenance information: Machine backup data, drawing, Modifications, Manuals, BD history, Countermeasures taken, analysis done etc.

 

16. Knowledge of SAP systems for procurement of spares & inventory management.
17. Knowledge about latest technological changes in industry – IoT, AI, Smart manufacturing. Experience of implementing projects in this.

 

18. Experience of working on projects related to IIoT & Cloud integration.
19. Experience of projects related to Digitization of maintenance & monitoring activities.

 

20. Knowledge about various sensors & controllers used for implementation of smart manufacturing projects.

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