1. Preventive Maintenance:
· Plan preventive maintains in coordination with production team for Zero Breakdown and ensure 100% availability of machines and equipment’s.
· Drive technical changes in preventive maintenance by considering the breakdown maintenance.
· Verifying Preventive Maintenance check sheet on daily & weekly basis to ensure PM as per the plan
· Making machine /Equipment available for preventive maintenance as per plan.
· Verifying equipment inspection check sheets to identify abnormalities and taking the necessary action to overcome on that abnormalities by making required part available, installation of part & servicing of that equipment / machine.
· Doing MTBF (Mean Time Between Failure) & MTTR (Mean Time to Repair) analysis and taking counter measure actions
· Following and updating TBM calendar for timely basis inspection to increase the life of spare part and machine equipment.
· Should align all the plan according to Quality Systems Requirements
· Club visits of Manufacturere /AMC provider during PM schedule
2. Breakdown Maintenance
· Attending the major breakdown maintenance to understand the exact problem by doing why-why analysis for taking counter measures
· Guide for counter measure activity after breakdown analysis like, restoring the defective parts & removing the abnormalities, taking trail of equipment to ensure normal functioning of the equipment etc.
· Review and analyze the day to day breakdown report & providing guidance to team as and when required.
· Monthly review of break down report to understand the occurrence & root cause for reducing MTTR & increasing MTBF.
· Prepare / suggest counter measure to prevent occurrence of the same problem/abnormality & ensure Horizontally deployment of the same through maintenance engineer.
· Develop local service provider for small repair Job in accord with Purchase
3. Spares Management
· Identifying critical and non-critical spare parts & time to time updating the spare part list as per requirement.
· Management of Spare part for consumable spares, Wearing spares, electronic spares & electrical switch gears.
· Controlling consumption of consumable, spare part and stock items.
· Identification of Indigenous spare part for cost reduction
4. Cost Saving & Energy Conservation
· Reducing inventory and saving cost by converting imported to indigenous, refurbishing and reuse, developing local vendors & alternate sources, also by inventing newest technology useful for company
· Interacting with service engineers & doing market research to identify the low cost & long-life parts & materials to reduce the cost of material and parts.
· Reducing service cost by inhouse training of maintenance team.
· Identifying the power wastage & plan for energy conservation through reduction of energy consumption, reuse of energy, circuit modification, using natural resources & alternate energy efficient resources.
5. Modification & Upgradation
· Identifying absolute & old equipment’s, machinery, spare parts and upgrading them as per new technology
· Upgrade and improve absolute machines though system modification as per the customer’s requirements and KAIZEN.
· Modification of the machine for improving MTTR & MTBF through analysis of past breakdowns and week design identification.
· Providing advance tools like Bearing pooler, hydraulic Jack, hydraulic trollies, lifter, multi-function meters to reduce breakdown hours.
· Should have small team to perform all Kaizen ideas, suggestions safety requirements
6. Manpower Management & Training
· Prepare manpower plan & weekly shift schedule & Monitor shift wise manpower availability & take necessary actions in case of manpower shortage to avoid productivity loss.
· Identify & escalate disciplinary issues to eliminate further losses.
· Identification of technical & soft skill requirements to develop and train manpower accordingly.
· Training existing & new manpower on system implementation.
7. Vendor & Service Management
· Identify and develop compatible vendors for service solutions, Machine Upgradation, Tool Room requirements, electronic services and upgradation & coordinating with vendors on timely basis to resolve problems, changing parameters Taking follow-up for payment of vendor
8. System Implementation and documentation
· Implementing systems like QMS, IATF, TS, 5S, TPM, DWM. Preparing the documentation and presentation of the same as per Statutory Requirement, audit requirement, management review, value working.
· Reviewing and maintaining records of all maintenance related activities in SAP
· Comply and percolate the statutory reequipments like OSHAS, EMS, Safety, MSEB.
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