Electrical Maintenance Engineer

TVS Indeon; Chennai District; On-site; INR 900,000 - 1,300,000; Full time

Job summary

TVS Indeon in Tamil Nadu, Chennai district is seeking an automation engineer to drive improvements on the shop floor. You will analyze production losses, implement corrective actions, and enhance OEE through PLC, robot and vision-system integration.

Responsibilities include programming Siemens S7-1500, Mitsubishi and ABB robots, FESTO servos, and vision/barcode systems, plus fault diagnosis, data logging, MES interface support and vendor coordination.

Qualifications

• Experience in automation maintenance and shop-floor support.
• Hands-on PLC, robotics and vision-systems familiarity.
• Willingness to work in shifts and coordinate with vendors.

Responsibilities

• Drive continuous improvement to enhance productivity, quality and efficiency.
• Analyze production losses and rejections; implement corrective actions.
• Improve OEE, reduce cycle time and rejects.
• Develop and troubleshoot PLC programs (Siemens S7-1500).
• Integrate PLC with HMI, SCADA and field devices.
• Electrical wiring studies and safety circuit considerations.
• Ensure proper control logic, interlocks and alarms.
• Program and maintain Mitsubishi and ABB robots.
• Optimize robot cycle time and path accuracy.
• Handle robot fault diagnosis and recovery.
• Maintain FESTO servo systems; SEW VFDs.
• Tune, align and synchronize motion; monitor welding parameters.
• Maintain AMADA resistance projection welding machines.
• Monitor welding quality; configure and troubleshoot barcode/vision systems.
• Configure SICK scanners; Keyence vision systems; Cognex and Zebra scanners.
• Ensure data communication with PLCs for inspection.
• Operate Chroma and Neware battery testers; analyze test data.
• Develop LabVIEW-based applications (BMS flashing station).
• Manage data acquisition, logging and MES interfaces.
• Maintain DDK/Atlas Copco nutrunner tooling; improve torque data.
• Maintain MEERA laser marking; ensure marking quality and PLC communication.
• Monitor marking clarity, traceability and quality compliance.
• Perform preventive, predictive and breakdown maintenance.
• Conduct RCA and implement countermeasures; maintain docs and logs.
• Track equipment uptime, MTTR/MTBF; reduce breakdowns.
• Improve FTQ, reduce rework and rejection; boost OEE.
• Coordinate new projects and installation support.

Tools

Siemens S7-1500 PLC

Mitsubishi robots

ABB robots

FESTO servo systems

Keyence vision systems

AMADA resistance welding

SICK barcode scanners

Cognex & Zebra scanners

Chroma & Neware testers

LabVIEW programming

DDK & Atlas Copco nutrunner

MEERA laser marking

Profinet / Ethernet/IP / Modbus

Job description

• Drive continuous improvement initiatives & Pro active approach to enhance productivity, quality, and efficiency.
• Analyse production losses , Rejection and implement corrective and preventive actions.
• Improve OEE, reduce cycle time, and minimize rejection rates.
• Develop and troubleshoot PLC programs (Siemens S7-1500).
• Integrate PLC with HMI, SCADA, and field-level devices. (Third party devices)
• Electrical wiring study (Safety circuit etc..)
• Ensure proper functioning of control logic, interlocks, and alarms.
• Program, troubleshoot, and maintain:
• Mitsubishi Robots - (Model :MELFA robot (4 axis))
• ABB Robots (6 Axis robot)
• Optimize robot cycle time and path accuracy.
• Handle robot fault diagnosis and recovery.
• Maintain and configure FESTO servo systems.
• SEW VFD system
• Perform tuning, alignment, and motion synchronization.
• Maintain AMADA resistance projection welding machines.
• Monitor welding parameters and ensure consistent weld quality.
• Configure and troubleshoot:
• SICK barcode fixed scanners
• Keyence vision systems & Checker
• Cognex & Zebra scanners
• Ensure accurate inspection and data communication with PLC systems.
• Operate and maintain:
• Chroma battery testers
• Neware battery testers
• Analyse test data and ensure system accuracy and reliability.
• Develop and maintain LabVIEW-based applications. (BMS flashing station)
• Manage data acquisition, logging, and communication interfaces. (MES )
• Maintain and troubleshoot:
• DDK nutrunner
• Atlas Copco nutrunner
• Analyse torque data and improve fastening quality.
• Maintain and troubleshoot:
• MEERA Laser marking
• Ensure accurate code reading, marking quality, and communication with PLC systems.
• Monitor marking clarity, contrast, and traceability compliance.
• Perform preventive, predictive, and breakdown maintenance.
• Conduct root cause analysis (RCA) for failures & Permanent countermeasure
• Maintain documentation, logs, and reports.
• Equipment uptime (%)
• MTTR / MTBF
• Reduction in breakdowns
• First Time Quality (FTQ) improvement
• Rejection and rework reduction
• OEE improvement
• New project co ordination & Installation support

Technical Skills

• PLC Programming (Siemens S7-1500)
• Robot Programming (Mitsubishi, ABB)
• Servo systems (FESTO)
• Vision systems (Keyence)
• Resistance projection welding (AMADA)
• Barcode systems (SICK, Cognex, Zebra)
• Battery testers (Chroma, Neware)
• LabVIEW programming
• Nutrunner (DDK, Atlas Copco)
• Laser marking (MEERA)
• Industrial communication protocols (Profinet, Ethernet/IP, Modbus)

Additional Requirements

Willingness to work in shifts

Ability to handle shop-floor challenges

Vendor coordination and project support experience