Engineer - Maintenance

Johnson Electric Group; Chennai District; On-site; INR 800,000 - 1,200,000; Full time

Benefits offered by this job

Inclusive and diverse workplace

Opportunities for growth and development

Job summary

Johnson Electric Group seeks an experienced Engineer - Maintenance in Chennai to ensure the reliability of high-speed automated DC motor assembly lines. The ideal candidate will have 5 to 8 years of relevant experience and a Bachelor's Degree in Electrical, Mechanical, or Automation Engineering.

This role focuses on equipment maintenance, troubleshooting automation faults, and implementing preventive maintenance practices to enhance productivity and reduce downtime.

Join a diverse team dedicated to improving quality of life through innovative motion systems.

Qualifications

• 5–8 years of maintenance experience in automotive or motor manufacturing.
• Experience in high-speed automated assembly lines is essential.
• Strong problem-solving and decision-making abilities are required.

Responsibilities

• Ensure >99% line availability for automated DC motor assembly lines.
• Diagnose and resolve high-speed automation faults impacting throughput.
• Drive preventive and predictive maintenance strategies to enhance equipment reliability.

Skills

High-speed automated assembly lines

DC motor manufacturing processes

PLC and motion control systems

Troubleshooting servo drives

Safety standards compliance

Education

Bachelor’s Degree in Electrical / Mechanical / Mechatronics / Automation Engineering

Tools

PLC

SCADA

HMI

Job description

## Engineer - MaintenanceApplylocations: India, Chennaitime type: Full timeposted on: Posted Todayjob requisition id: R00030228**Position: Engineer Maintenance****Experience: 5 to 8 years****Role Purpose**Engineer – Maintenance is responsible for ensuring **maximum uptime, reliability, and performance** of **high‐speed automated DC motor assembly lines**. The role focuses on maintaining and improving integrated, multi‐station single‐piece‐flow assembly lines with MES systems, while driving predictive, preventive and breakdown maintenance excellence.**Key Responsibilities****1. Assembly Line & Equipment Maintenance*** Ensure **>99% line availability** for fully automated DC motor assembly lines operating at **1‐second cycle time**.* Lead maintenance of processes including: + Armature/coil **winding machines** + **Fusing machines** + **Soldering stations** (automatic soldering, induction soldering) + **Motor performance testing stations** (electrical, torque, RPM, noise, vibration)* Handle maintenance for **40+ stations integrated &** connected through **single piece flow conveyor systems**.* Own troubleshooting of **complex interlocks, station handshakes, and line balancing issues**.**2. Automation, Controls & Systems*** Strong ownership of **PLC, HMI, SCADA, servo drives, vision systems**, safety PLCs, and sensors.* Diagnose and resolve **high‐speed automation faults** impacting takt time and throughput.* Work closely with automation vendors and OEMs for: + Root cause analysis + Software modifications + Cycle time improvements* Ensure robust **backup, version control, and change management** for automation programs.**3. Preventive & Predictive Maintenance*** Define and deploy **Preventive Maintenance (PM)** and **Predictive Maintenance (PdM)** strategies suitable for high‐speed lines.* Drive **condition monitoring** (vibration, thermal, current signature analysis) for critical stations.* Reduce **MTTR** and increase **MTBF** through structured maintenance practices.* Maintain and improve equipment **OEE**.**4. Breakdown Management & Root Cause Analysis*** Lead fast, structured **breakdown response teams** for line‐stopping issues.* Conduct **RCA (Why‐Why, Fishbone, 8D)** for chronic and repetitive failures.* Implement permanent corrective and preventive actions (CAPA).* Track breakdown data and lead continuous improvement initiatives.**5. Continuous Improvement & Cost Optimization*** Drive **cycle time stability** in 1‐second takt environments.* Support **lean manufacturing**, **TPM**, Kaizen, and reliability improvement projects.* Reduce maintenance costs through: + Spare parts optimization + Reliability redesign + Vendor performance management* Support capacity expansion, line duplication, and automation upgrades.**6. Team Leadership & Capability Building*** Lead, coach, and develop a team of **maintenance engineers, supervisors, and technicians**.* Ensure round‐the‐clock maintenance coverage aligned to production shifts.* Build strong **troubleshooting capability** for high‐speed automated equipment.* Drive safety culture and compliance within the maintenance team.**7. Spares, Documentation & Compliance*** Ensure critical spares availability with optimal inventory levels.* Maintain updated equipment documentation, SOPs, PM schedules, and electrical drawings.* Ensure compliance to **safety standards, quality systems, and audit requirements** (ISO, IATF, EHS).**Key Skills & Competencies****Technical Skills*** Expertise in **high‐speed automated assembly lines** (≤1 second cycle time)* Strong knowledge of **DC motor manufacturing processes*** Advanced troubleshooting of: + PLCs & motion control systems + Servo drives & robotics + Vision systems and functional testing stations* Conveyor systems with **single piece flow*** Electrical, mechanical, pneumatic, and control systems integration**Behavioral & Leadership Skills*** Strong problem‐solving and decision‐making abilities* Ability to work under **high‐pressure, zero‐tolerance downtime environments*** Effective communication with production, quality, and engineering teams* Results‐driven, hands‐on leadership style**Qualifications & Experience*** **Bachelor’s Degree** in Electrical / Mechanical / Mechatronics / Automation Engineering* **5–8 years** of maintenance experience in: + Automotive + Motor manufacturing + High‐speed automated assembly lines* **5+ years** in a maintenance leadership/managerial role preferred**Key Performance Indicators (KPIs)*** Line availability / OEE* MTTR / MTBF* Breakdown frequency and severity* PM compliance* Maintenance cost vs budget* Safety incidents (zero tolerance)**Working Environment*** High‐volume, fast‐paced manufacturing environment* 24/7 operations with critical uptime requirementsHands‐on engagement with shop floor and automation systems***Come join our global, inclusive & diverse team***Our purpose is to improve the quality of life of everyone we touch through our innovative motion systems. We are a truly global team bound together by our shared values. Our culture is built on the diversity, knowledge, skills, creativity, and talents that each employee brings to the company. Our people are our company’s most valuable asset. We are committed to providing an inclusive, diverse and equitable workplace where employees of different backgrounds feel valued and respected, regardless of their age, gender, race, ethnicity or religious background. We are committed to inspiring our employees to grow, act with ownership and find fulfilment and meaning in the work they do.