Mechanical Maintenance - Level III

Job Summary:

Troubleshoots, assembles, installs, tests and maintains mechanical systems using all necessary tools to keep equipment available and capable. Learns and understands the protocols of working safely with electricity and other energy sources with industrial equipment. May work independently and instruct or coach others.

Key Responsibilities:

Health, Safety & Environmental (HSE)
Stop work and immediately report any major injury hazards.
Report any work-related injury, illness, incident or hazard.
Comply with HSE standards, policies, procedures and regulations.
Use appropriate personal protective equipment.
Promote interdependence by looking out for one another.
Correct hazards within your control and capabilities.
Recognize how your work may impact the environment and work to minimize the negative impact.
Engage in HSE Training.
Quality
Applies high standards of workmanship and craftsmanship.
Support equipment uptime and downtime failure analysis.
Performs work in accordance with diagrams, sketches, operation manuals and specifications using various tools, measuring and testing instruments.
Provide feedback into the Preventive Maintenance system.
Follows all process documentation and quality procedures.
Raises issues to minimize cost and quality exposures.
Performs quality inspections.
Delivery
Fully proficient performing troubleshooting, mechanical repairs and maintenance of equipment .
Instructs and coaches others and acts as an informal resource for team members with less experience.
Perform and documents preventive, emergency, corrective and predictive maintenance activities.
Maintains clean and orderly work area, including routine housekeeping and machine cleaning tasks.
Performs other miscellaneous duties as required to meet production goals.
Identify and reduce manufacturing constraints
Schedule maintenance activities around production requirements
Solve problems and improve processes
Participate in continuous improvement activities
Teamwork
Communicates effectively with the assigned team and with all support teams.
Completes training and personal development in line with business requirements.
Participates actively with local Total Productive Maintenance (TPM) teams in ways to improve quality, safety, process, material flow, and employee development.

Education & Experience:

Diploma in Mechanical or Mechatronics Engineering with 8 to 10 years of experience in ATPU ()

Job Description:

- Technical knowledge of ATPU Equipment – e.g. Nut Runners, Test Cells, Wash Booth, Paint Booth, TOD, Turn Table, PRCs.
- Thorough knowledge of mechanical maintenance of all equipment in both ATPU – NK & KV.
- First priority should be for “Zero Engine Loss” .
- Sound technical knowledge of all Nut Runners, their mechanisms, TODs, Wash Booth, Paint Booth, etc.
- Should have good technical knowledge of all Test Cells, Dyno maintenance, Butterfly Valve maintenance, etc.
- Sound technical knowledge of all types of Smoke Meters, Heat Exchangers and Coolant Conditioning Units.
- Should have sound technical knowledge of all types of Tuggers used for engine movement.
- Should be fully conversant with CMES projects.
- Sound technical knowledge of all types of Paint Pumps – pneumatic as well as electrically operated.
- Should be conversant with all types of Goods Lifts used in both ATPU.
- Should be fully conversant with Kardex machines, Dock Levelers and Goods Lifts.
- Sound technical knowledge of Fast Acting Doors, Ovens, Dryers, etc.
- Maintaining all Plant Engineering KPIs – MTTR, MTBF, PM Compliance, Craft Utilization, etc.
- On-time reporting of all types of Near Hits and Spill Incidents in the ATPU Maintenance area.
- Carrying out all improvement projects related to HSE, Quality, Maintenance, etc.
- Good Communication and Presentation skills.
- Should have good people connect – internal stakeholders as well as external suppliers/customers.
- Conduct regular meetings once a month with ATPU Leader & PE Leader.
- Good connect with ATPU Process Team as well as Quality Team.
- Manage installation and commissioning of machines/equipment at ATPU.
- Interfacing of automated material handling systems with the machines at ATPU.
- Consistently maintain and improve Housekeeping standards.
- Implementation of safety systems – Job Safety Analysis, Risk Assessments, Work Permits and LOTO related to maintenance activities in Machine Shop.
- Maintain discipline of the workforce.
- Spare parts planning and inventory management based on VED or other analysis tools.
- Giving timely feedback on progress/issues to BU / Maintenance Leader.
- Knowledge of Assembly Lines and Manufacturing Fundamentals.
- Good Communication skills and Knowledge of Computers.
- Knowledge and hands-on experience in Hydraulics and Pneumatics is a must.
- Should have thorough knowledge of AVL Smoke Meter operation, maintenance, calibration and troubleshooting , including sampling systems, AUTO mode, flow, leakage, grey value and communication-related issues.
- Should have good technical knowledge of Dyno F47 and F35 systems , including dyno operation, loading/unloading, speed and torque control, calibration, interlocks and troubleshooting.
- Sound technical knowledge of ASU Blower systems , including blower operation, VFD control, pressure/flow monitoring, dampers, interlocks and troubleshooting.
- Should have sound technical knowledge of Test Cell instrumentation and control systems , including PLC, HMI/SCADA, sensors, transducers, RTDs, thermocouples, Analog/Digital I/O and DAQ systems.
- Should have good knowledge of Test Cell utilities and associated equipment , including Heat Exchangers, Coolant Conditioning Units, pumps, valves, Butterfly Valves and associated control systems.
- Ability to troubleshoot Test Cell interlocks, engine safety systems, emergency shutdown systems and equipment permissive to minimize engine downtime.
- Should be capable of analyzing and troubleshooting Test Cell load variation, pressure/flow fluctuations, temperature variation, instrumentation and communication-related issues .
- Ensure maximum Test Cell availability and minimum Engine Loss through effective PM, breakdown response, RCA and reliability improvement activities.
- Should coordinate effectively with Test Cell Process, Quality, Engineering, PE teams and external OEMs/Suppliers for troubleshooting, calibration, maintenance and improvement activities.