Job Description
Job Overview:
Ensure safe working environment in the plant to make accident free plant.
Target to achieve Availability of Production lines and benches with Zero production down time by adopting best maintenance practices
Improve the machine /line efficiency level more than 100% by continual improvement and modifications in machines
To develop Technical competency for Maintenance team autonomy by training and development
Monitoring of established systems and make sure will be followed by team
Up keep and build safe inventory critical spares and monitoring by adopting MIMS
| AREAS OF RESPONSIBILITY (Describe the nature, scope, level of improvements to new ideas, etc.) | LEVEL *(Full, Partial, Supportive) | MEASUREMENT (Quantitative or quality criteria to achieve responsibility) |
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| Planned Maintenance Categorize the machines into ABC machines depending on the criticality of the machine for the business. Identify the maintainable components in the machines. Define the type of maintenance required for the maintainable components. Prepare the work instructions the planned maintenance activities. Prepare the preventive maintenance schedule for the whole year. Allocate resources to handle planned maintenance on a daily basis. Track the planned maintenance implementation and update records. Evaluate the effectiveness of planned maintenance. Update the work instructions and schedules based on the evaluation and improvements. | Partial | % completion on time |
| Automation Decide appropriate automation solution for manual process. Design electrical / elecro pneumatic automation circuts. PLC programming, troubleshooting, machine up gradations to improve machine availability | Full | Machine availability, MTTR, MTBF |
| Reactive Maintenance Ensure repair of machines during breakdowns. Pool the available resources and immediately take action to rectify the problem and resume production. Analyse the root cause analysis of the failures and implement improvement plan. Report failures and actions for loss of availability of machines. Work towards bringing down the down time due to breakdowns / non availability of machines. | Partial | % availability; MTTR and MTBF |
| Predictive maintenance Identify maintainable components for predictive maintenance. Prepare schedule, organize resources; monitor the signatures; analyse the data pattern on the failure mode and plan for resource and maintenance requirements | Partial | % completion on time |
| Spare Parts Management Prepare the plant tree – determine the maintainable components of a particular machine in a particular location in the plant. Link the work instructions to the maintainable components; Arrive at safety stock requirements based on Vital Essential Desirable (VED analysis), cost, lead time analysis. Identify the population and required stock levels of the parts. Identify suitable vendors and plan for procurements of parts on time. Localize the parts as and when required. Work towards redesign for improving the lifetime of parts / components. Follow –up for outsourced service of parts; Stock the parts at right levels at right location. Track receipts and issues of spare parts. | Partial | Number of lost hours due to parts |
| Legal / Regulatory requirements Ensure Calibration of equipments, Perform aspect / impact and hazard – risk analysis for maintenance activities. Identify the methods and create disposal procedures for hazardous waste. Ensure compliance with statutory requirements pertaining to equipments and installations. Adhere to QMS, EMS and OSHAS guidelines and update the records, system.
| Partial | Compliance status No: of major NCs |
| Annual Maintenance Contract Identify vendors / service providers for AMC for various for manufacturing equipments. Prepare comparative charts based on past performance and submit to manager maintenance for approval; After signing of agreement coordinate with the service providers and ensure proper provision of service and maintenance of appropriate records; Offer constructive feedback to the service providers to ensure efficiency; Discuss various ways and means of upgrading the system | Partial | %completion |
| SPS Implémentation (TPM / Six Sigma) Identify problem areas requiring six sigma approach. Manage the resources to complete the project on time. Follow 6 sigma methodologies to provide solution for the problem. TPM - understand and build systems to implement TPM as part of SPS guide lines. ensure adherence of SPS. | Full | SPS Score |
| Team management, training Prepare the shift schedule and effectively use people to execute the maintenance work. Prepare skill matrix and identify training needs for them Train them and bring awareness on various systems including TPM, 5 S, QMS , EMS and other concerned SPS programmes. Track their performance and give effective feedback. Motivate them to continually make improvements and also improve their performance. | Partial | MTTR (Mean time to repaira0 , MTBF (Mean time between failure. |
| Budget support: Plan maintenance activities for next year. Perform facility planning based on requirements. Identify cost required for the facilities and maintenance activities. Prepare budget requirements and discuss the same with manager maintenance. | Supportive | Adhere to budget limits |
*Full : Fully responsible for the results of the work
Partial : Partially responsible for the results of the work
Supportive : Provide support to the person accountable for the results of the work.
