Mechanical Maintenance - Level III

 Key Responsibilities A. Machine Maintenance

      A. Machine Maintenance

• CNC machines (VMC, HMC, Turning Centers)
• Conventional machines (lathe, milling, grinding)
• Special purpose machines (SPMs)
• Transfer lines / assembly-linked equipment
• Check and maintain:
  • Spindle systems
  • Ball screws & linear guides
  • Automatic tool changers (ATC)
  • Hydraulic & pneumatic systems

B. Preventive & Predictive Maintenance

• Execute PM schedule for all machines
• Perform:
  • Lubrication audits
  • Backlash & alignment checks
  • Vibration & temperature monitoring
  • Coolant system maintenance
• Ensure 100% PM compliance

C. Breakdown Maintenance

• Attend machine breakdowns with fast response time
• Diagnose faults (mechanical, hydraulic, basic PLC interface support)
• Reduce MTTR (Mean Time to Repair)
• Implement RCA & CAPA to avoid recurrence

D. Accuracy & Quality Support

• Ensure:
  • Machine geometry accuracy
  • Dimensional consistency of output
• Support:
  • Trial runs after maintenance
  • Root cause analysis for rejection due to machine issues

E. TPM & Continuous Improvement

• Drive:
  • Autonomous Maintenance (JH pillars)
  • Kaizen projects
• Focus on:
  • Breakdown reduction
  • OEE improvement
  • Setup time reduction

F. Safety & Compliance

• Strictly follow:
  • LOTO procedures
  • Work Permit system
  • Machine safety standards
• Ensure:
  • Guarding & interlocks functionality
  • Safe practices during maintenance

G. Documentation & CMMS

• Update:
  • Breakdown history
  • PM checklists
  • Spare consumption
• Use CMMS (e.g., IBM Maximo) for:
  • Work orders
  • Asset tracking

H. Spare & Inventory Support

• Identify critical spares:
  • Bearings, seals, belts, filters
  • Hydraulic components
• Support:
  • Inventory control
  • Vendor coordination

3. Key Performance Indicators (KPIs)

• Machine uptime: > 95–98%
• PM compliance: > 95%
• MTTR reduction
• Breakdown frequency reduction
• OEE improvement (%)
• Rejection due to machine issues (↓)
• Safety incidents: Zero

Competencies: 
Collaborates - Building partnerships and working collaboratively with others to meet shared objectives. 

Communicates effectively - Developing and delivering multi-mode communications that convey a clear understanding of the unique needs of different audiences. 

Customer focus - Building strong customer relationships and delivering customer-centric solutions. 

Decision quality - Making good and timely decisions that keep the organization moving forward. 

Drives results - Consistently achieving results, even under tough circumstances. 

Manages complexity - Making sense of complex, high quantity, and sometimes contradictory information to effectively solve problems. 

Nimble learning - Actively learning through experimentation when tackling new problems, using both successes and failures as learning fodder. 

Health and Safety Fundamentals - Champions and models proactive health and safety behaviors by identifying, reporting and participating in actions to improve health and safety in order to build an interdependent culture and contribute to an injury-free workplace. 

Controls Safety - Recognizes controls related hazards in a manufacturing environment (Electrical, Hydraulic, Pneumatic) to incorporate safe practices and procedures as part of the daily work plan to reduce injuries and create a safe machine environment. 

Manufacturing Knowledge - Demonstrates the knowledge of manufacturing by correctly implementing changes in current processes, equipment, and applications to meet the function's needs and contribute towards continuous improvement. 

Values differences - Recognizing the value that different perspectives and cultures bring to an organization. 

Education, Licenses, Certifications: 
High school diploma or certificate of completion of secondary education or equivalent experience to the extent such experience meets applicable regulations. 
This position may require licensing for compliance with export controls or sanctions regulations. 

Experience: 

• 6–8 years (Diploma)
• Hands-on experience in machine shop maintenance

 

1. Technical Skills

• Strong knowledge of:
  • CNC machine mechanics
  • Hydraulics & pneumatics
  • Bearings, lubrication systems
• Familiar with:
  • Machine leveling & alignment
  • Drawings & machine manuals
  • Basic PLC/controls coordination (preferred)

2. Behavioral Competencies

• Strong troubleshooting skills
• High ownership & accountability
• Quick decision-making under breakdown situations
• Team coordination with production & quality
• Continuous improvement mindset

3. Preferred Certifications

• TPM / Lean Manufacturing
• CNC maintenance training (OEM specific preferred)
• Safety certifications (LOTO, machine safety)

4. Working Conditions

• Shop-floor based role
• Shift working (if applicable)
• Exposure to machining environment, coolant systems, noise

Skills / Competencies :-   
1)     Diploma in Mechanical engineering.
2)    Knowledge of Machine tools, manufacturing fundamentals.
3)    Good Communication skills & Knowledge of Computer operating
4)    Good Analytical skills with proactive approach
5)    Team player & Basic knowledge of Health & safety 
6)    Knowledge of Basic PLC, Electrical drawings reading, Electrical troubleshooting, KUKA & FANUC robots troubleshooting, CNC controller Knowledge will have added advantage.
7)    Basic Knowledge of TPM, 5S, RCA techniques etc.