Process Eng Junior Engineer

Overview

Ensuring that all Packaging 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 ensuring the machines are being maintained at their Basic Condition.
• Review of daily breakdowns with the technician/electricians, deploy manpower for the maintenance jobs and coordinating with him about the same.
• Raising PR (purchase requisition) in ARIBA to source the spares and services from OEM/vendors.
• Attending daily management wall and packaging wall meeting to understand the ongoing concerns and support required.
• Interacting with the mechanical/electrical contractors to get 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 must be carried out for the machines which reflect defects on repetitive basis.
• Reviewing the daily production plan and 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.
• Reviewing and monitoring 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 packaging machines.
• Supervising the fitter and electrician who carry out the actual overhauling.
• Maintaining history sheets of overhauling and preventive maintenance schedules.
• Conducting the Root Cause Analysis for the repetitive breakdowns and for the breakdowns >1 hour.
• Contribute to the PeMM (PepsiCo Excellence Maintenance Methodology) by working on the relevant workstreams.

Responsibilities

• Submitting ABC analysis of spares.

• Specifying in consultation with the engineering stores in charge, 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 to achieve standardization of purchase rates.

• Creating the material code in SAP for engineering spares and catalog creation for the engineering services and spares.

• Development of local vendors to either replace or repair the OEM parts to get better prices/quality.
• Monthly review of R&M expenditure line wise and improvement plans as applicable.
• Yearly review of Packaging Engineering Spares and classify them as working, insurance & obsolete.

• Monitoring the utilization of the annual budget
• Developing and sourcing indigenous spare parts to replace defective imported spare parts.

• 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.
• liaison Ing with the Weights and Measures Department to fix their visits to the plant.

• Maintaining all the statutory documents needed as per the Weights and Measures Department.
• Online compliance reporting as per the Weight & Measurement Act in the online compliance portal of PWC.

Providing assistance to the engineering manager on various issues

• Providing relevant information to the engineering manager for the phase-out of obsolete machinery and purchase plans for new technology
• Providing relevant figures on the history of machine breakdowns to help him design a maintenance system.
• Assisting the engineering manager in formulating CAPEX proposals by bringing to his notice various developmental issues for machines
• Inviting technical quotes from the competent vendors/OEMs and preparing the technical bid analysis/summary.
• Maintaining proper documentation of all history cards, MTBF etc.
• Drive Recon initiatives to conserve energy by mitigating the compressed air leakages.

3.     Contributing as a team member of the engineering department to develop a high performing and skilled engineering team

• Drive the development of PCI/NPCI team of technicians for electrical / mechanical maintenance by providing them OJT from OEM service engineers.

4.     Participating in various TPM, EHS & Quality activities to understand the functioning of the various plant systems and contribute cross-functionally:

• Analyzing collectively the problem taken up by the group
• Designing solutions/ suggestions to the specific projects/ problems taken up by the TPM
• Implementation of the solutions
• Internalizing the TPM culture
• Certifying themselves as Kaizen Champion Green/Red/Black Belt ??
• Drive applicable EHS GEHSMS standards to role & responsibilities, create awareness at shop floor team for timely support and      execution, and its compliances.
• Mitigation of identified in near miss and safety related findings and monthly participation in safety committee meeting.
• Ensuring MESS compliance of all the legacy & new equipment’s.

• Drive MFS (maintenance for food safety) pillar under AIB Audit for the packaging area.

Qualifications

• Education: B. E/Diploma ( Electrical/Instrumentation/Electronics/Mechanical)
• Desirable: Diploma/ degree in Continuous Packaging Line
• Functional Experience: Approx. 4-7 years of experience
• Language: English, Hindi

• Minimum experience of 2 years of working in a similar industry at the supervisory level
• Experience of handling automated packaging machines
• Exposure to other companies’ manufacturing systems and shop floor culture