Job Title: Electrical Maintenance Lead

Location: Nashik, Maharashtra

Department: Maintenance

Reports to: Plant Manager / Operations Head

Job Purpose:

The Electrical Maintenance Lead is responsible for overseeing the maintenance, repair, and optimization of all production process machines, utility systems, and refrigeration systems at the fruit processing facility. The role ensures equipment reliability, minimizes downtime, and maintains efficiency and safety across all electrical systems.

Key Responsibilities:

- To practically handle maintenance activities on the shop floor as an Electrical Maintenance Lead, a hands-on approach is crucial. This involves balancing leadership and technical expertise by actively participating in breakdown resolution, supervising preventive maintenance, and ensuring efficient shop-floor operations. Here's how you can effectively manage maintenance activities while being hands-on:

- To effectively manage manpower and handle the team in a way that Preventive Maintenance (PM) leads to zero breakdowns, a systematic approach is essential.

1. Lead by Example - Get Involved in Breakdowns:

Quick Response to Breakdowns:

- When a machine breaks down, be physically present on the shop floor. Assess the situation alongside your team, helping them troubleshoot and resolve the issue faster. Your active participation boosts morale and demonstrates leadership.

Hands-On Diagnostics:

- Utilize your technical expertise to diagnose electrical faults, PLC issues, motor failures, or utility system problems. Work closely with technicians to guide them through complex problems, teaching them how to troubleshoot similar issues in the future.

Support with Tools and Knowledge:

- Step in during critical breakdowns with your own set of tools and knowledge. Be prepared to work with equipment such as multimeters, thermal cameras, and vibration analyzers to help pinpoint issues. If needed, jump in and physically assist in dismantling or repairing a component.

2. Involvement in Preventive Maintenance (PM):

Join Technicians During PM Activities:

- For key equipment, participate in preventive maintenance tasks. This gives you real-time insight into machine conditions, the effectiveness of the PM schedule, and the team's efficiency in handling maintenance tasks.

Hands-On Verification:

- During PM activities, check electrical panels, motors, control systems, wiring, and insulation conditions yourself. Double-check the work of your technicians to ensure the highest standard of quality in maintenance.

Spot Training Opportunities:

- Use PM time as an opportunity to train junior staff by demonstrating best practices for lubrication, component inspections, and electrical troubleshooting. Teach them about safety practices while they work hands-on with equipment.

3. Supervise the Maintenance Workflow:

Stay On the Shop Floor:

- Spend a significant portion of your time on the shop floor, overseeing ongoing maintenance tasks. Monitor technician efficiency, safety, and adherence to protocols. This allows you to step in quickly if an issue arises.

Problem Solving in Real-Time:

- Act as a resource for your team when they encounter challenges during maintenance tasks. Help them come up with quick and practical solutions, whether it's adjusting the maintenance schedule or sourcing a quick spare part.

4. Develop a Strong Preventive Maintenance System:

Hands-On Maintenance Planning:

- Work closely with your team to plan preventive maintenance in a way that is both practical and effective. Make sure tasks are spread out to avoid overwhelming the team, and ensure downtime for PM is well-coordinated with production.

Equipment-Specific Checklists:

- Develop equipment-specific PM checklists that guide the team step-by-step. These should include electrical component checks (wiring, relays, contactors), lubrication of moving parts, cleaning of electrical panels, and visual inspections.

On-the-Job Adjustments:

- Be flexible. If you see that a PM task is taking too long or affecting production, make on-the-spot adjustments to the schedule while ensuring critical tasks are still completed.

5. Real-Time Monitoring and Troubleshooting:

- Condition Monitoring Tools:

- Use tools like thermal cameras, vibration sensors, and power analyzers to monitor equipment health. Teach your team how to interpret data from these devices and take preventive actions before a major breakdown occurs.

Troubleshooting on the Go:

- During normal operations, be available to quickly troubleshoot minor issues. Whether it's adjusting a control system parameter, resetting a PLC, or inspecting a motor's electrical connections, swift intervention can prevent small issues from escalating into breakdowns.

6. Collaborate with Production Teams:

- Coordinate with Production Supervisors:

- Regularly engage with the production team to understand operational bottlenecks and adjust your maintenance plan accordingly. This hands-on coordination ensures minimal disruptions to production schedules while ensuring equipment health.

Feedback Loop:

- Establish a direct feedback loop where production operators report any abnormal machine behavior or small electrical issues immediately. This allows you to intervene before small issues turn into costly breakdowns.

7. Resource and Spare Parts Management:

Keep Critical Spares Available:

- Be actively involved in inventory management by regularly reviewing spare parts stocks. Ensure essential electrical components (fuses, relays, motors, circuit breakers) are always in stock for immediate repairs.

Quick Repair Solutions:

- For urgent repairs, make quick decisions to either repair in-house or outsource. If a spare part isn- t available, find creative temporary solutions to get the machine running until proper repair is possible.

8. Performance and Safety Focus:

Implement Safety Protocols Hands-On:

- Always enforce electrical safety protocols, particularly during maintenance and repair work. Be present to ensure that Lockout/Tagout (LOTO) procedures, personal protective equipment (PPE) usage, and electrical hazard management are strictly followed.

Real-Time Performance Monitoring:

- Assess equipment performance after every repair and PM activity. Compare actual machine performance with historical data to identify improvements or further actions needed.