Assistant Manager Maintenance

Ensuring that all machine maintenance activities are carried out to minimize machine breakdowns

• Preparing schedule for machine maintenance (weekly, monthly and annual) from OEM manuals and list of requirements from packing leaders/ process??
• Obtaining resources for conducting this maintenance
• Raising indents for spare parts required
• Getting indents approved by the Plant GM
• Specifying manpower requirements for maintenance jobs to the Sr Engg Officer and coordinating with him about the same
• Interacting with the contractors for getting any breakdown related jobs done
• Doing hands-on repair work for machines at the time of electronics related breakdowns; example handling of PCB Cards, weighers and N2 flushing machines
• Prioritizing the maintenance jobs that have to be carried out for the machines
• Coordinating with production for timely release of machines for shut down activities/ preventive maintenance
• Sanctioning the replacement of high value spares after analyzing the breakdown cause and the need for replacement of the spare part.
• Monitoring the maintenance activities on regular maintenance days (Saturday of every week)
• Reviewing the maintenance activities at the end of the day and ensuring that all scheduled activities have been carried out
• Submitting a weekly machine efficiency report to the Plant Manager and the Engineering Manager
• Ensuring annual overhauling of all packing machines:
• Replacing carriage assembly moving parts (which are directly involved in bag sealing) with the new parts
• Raising RAR (R&M Appropriation Request) for the approval of Director Operations
• Planning for shutting down the machine for two days
• Arranging required spare parts with the Plant GMs approval
• Supervising the fitter and electrician who carry out the actual overhauling

Maintaining history sheets of overhauling and preventive maintenance schedules

Ensuring that the engineering stores carries the optimum amount of inventory at all times

• Submitting ABC analysis of spares
• Specifying in consultation with the engineering stores incharge, the minimum stock to be kept for each spare part
• Obtaining the weekly R&M spending list from Accounts to know the quantity and value of the spares consumed over the past week
• Checking levels of various spare parts related to the packaging machines at regular intervals (once/twice a week) to ensure that minimum level of spare parts are maintained
• Raising indents for the spare parts as and when they reach the minimum level keeping in mind the consumption pattern of the part, maintenance schedules and the lead time for purchase
• Getting indents approved from the plant manager and engg manager if the spare parts are imported and from the engg manager alone if the spare parts are local

Developing standard vendors for parts that are needed repeatedly in order to achieve standardization of purchase rates

Substituting the defective spare parts in the packaging area with indigenously developed spare parts in order to achieve cost optimization

• Monitoring the utilization of the annual budget
• Developing and sourcing indigenous spare parts to replace defective imported spare parts
• Sourcing of vendors
• Assessing the service capability of the vendors
• Testing the defective part to get material description and supplying the same to the vendor
• Testing the prototype received from the vendor on the machine
• Conducting preliminary negotiations with the suppliers on the rates of the part
• Raising indent for the spare part if the tests approve it
• Getting indents approved
• Ensuring that the indigenization activity is within the specified budget limits

Ensuring statutory compliance in the packaging area

• Preparing and implementing a statutory calendar for own area of work
• Guiding the operators in machine settings so that the weight, batch number, packing date etc. printed on the ready SKUs match with actual.
• liaisoning with the Weights and Measures Department to fix their visits to the plant
• Maintaining all the documents needed for the Weights and Measures Department visit

Carrying out instrumentation for packaging machines

• Carrying out upkeep, maintenance & calibration of instruments fitted in packing machines. It includes PLCs, temp. controllers, sensors, AC drives, DC drives, Servo drives & Stepper motor drives etc.
• Undertaking certain up gradation activities
• Calibrating the temperature controllers annually
• Engaging an external programmer for PLC programming
• Conducting improvement activities for the packaging machines in order to ensure a machine efficiency of more than 85% at all times
• Guiding the technicians for carrying out various improvement activities so that there are minimum cases of air leakage or film wastage; for example installation of PID temperature controllers to keep the temperature variation limited to +/- 10 C

Qualification & Experience:

• B.E/B.Tech Mechanical with minimum 7-8 years with FMCG experience
• Functional Experience: Approx. 6-8 years of experience in Food industry in maintenance function, experience of managing developmental projects in a plant scenario.
• Language: English, Hindi, and local language