Maintenance Engineer

Job description

Safety

a. Leading all Maintenance on site with compliance to site safety requirements

i. Developing and maintaining task registers for Routine vs Non-routine activities

ii. Developing and maintaining Risk assessments for Routine activities

iii. Closing all identified risks from risk prediction activities in ALL areas of the factory that fall under Technical team.

b. Key responsible for Machinery safety (supporting site competent person) on the site

2. Maintenance

a. a. Responsible for complete factory maintenance, breakdowns and MTBF & MTTR KPIs

i. Plantwide breakdown analysis

1. Daily tracking and analysis of ALL breakdowns

2. Detailed root cause analysis for all TOP breakdowns

3. Implementation of corrective actions from analysis and actions coming out of all other teams (quality, safety etc)

ii. Reduction of Breakdowns in numbers and % contribution to OEE loss in packing (approx. 60 Machines)

1. Developing Maintenance Plans

2. Ensuring maintenance plans reach to component level

3. Executing planned maintenance activities and ensuring OTIF compliance

4. Tracking maintenance compliance against breakdown reduction

5. Lead all major and minor modifications for OEE Improvement

iii. Reduction of Breakdowns in numbers and % contribution to OEE loss in making (approx. 800 Equipment e.g. valves, pumps etc)

1. Developing Maintenance Plans

2. Ensuring maintenance plans reach to component level

3. Executing planned maintenance activities and ensuring OTIF compliance

4. Tracking maintenance compliance against breakdown reduction

5. Lead all major and minor modifications

iv. Reduction of Breakdowns in numbers and % contribution to OEE loss in Utilities (approx. 800 Equipment e.g. valves, pumps etc)

1. Initiating, Negotiating & Managing Annual maintenance contract for Utilities equipment

2. Ensuring all utilities equipment maintenance is done on time, in full

3. Lead all major and minor modifications

v. Selection and Maintenance of specific mechanical and electromechanical components

1. Able to analyze deterioration of different components with time, force, pressure, temperature, use etc

2. Able to provide basic design (including engineering drawings + P&ID) and selection of components based on process parameters, user requirements and usage conditions

3. Go into in depth analysis of failure modes of components

3. Lead the automation agenda with electrical engineer for the site

a. Understand and tabulate requirements

b. Give basic system design for automation projects

c. Calculate cost/benefit ratios

4. Cost

a. Maintenance Cost tracking against volumes/other variables

b. Develop forecast models for all R&M Cost

c. Track FC vs Actual Weekly cost

d. Forecast R&M Budget in line with PM plans

i. Line wise breakup

ii. Cost phasing for R&M Budget

iii. Track spends against forecast

e. Identify reduction opportunities in all cost (Utility + R&M + Manpower) to meet factory cost target year on year

5. WCM

a. PM (professional maintenance) PILLAR KEY MEMBER

b. Core member of

i. AM

ii. QM

6. Key support for

a. All innovation projects

b. All cost & Energy related projects

c. All projects executed by Unilever Engineering

KEY SKILLS REQUIRED:

1. Able to demonstrate EXCELLENT engineering acumen – design and analysis of parts, machines, systems using

a. 3D modelling software

b. Autocad

c. FEA (finite element analysis methods)

d. Theoretical data for machine & system design

2. Expertise in mechanical equipment and electromechanical equipment and related components (e.g. packing and filling lines, pumps, heat exchangers, components such as bearings pneumatic cylinders)

3. Excellent knowledge of Condition Based Maintenance

4. Excellent analytical skills

a. Can analyze large quantities of data QUICKLY to identify correlations and trends

b. Can use small quantities of data (where full year is not available) and make calculated scientific assumptions to identify trends

c. Identify opportunities of improvement by understanding data trends

5. Excellent presentation and Soft skills

a. Expert knowledge of MS Excel to be able to build efficiency and energy prediction models

b. Able to present information and trends to the management in an easy to understand and action-oriented way

6. Excellent Bias for action

a. Able to respond to factory and stakeholder needs on time

b. Able to deliver all projects On time in full

7. Mechatronics/Electrical/Electronic/Mechanical Engineer with experience in Manufacturing and Maintenance