Job Description

Overview:Purpose/ Key Role

• Up keeping Packaging machines and ensuring equipment availability at all times.
• Ensuring Volume compliance, True Efficiency, Net Efficiency of all packaging lines.
• Ensuring Preventive Maintenance, Planned Maintenance.
• Minimizing Scheduled and Unscheduled downtimes, reduction of breakdown hours inline with Aspirational targets of the Plant
• Ensuring Ontime RCA closure and Red Tag Compliances
• Adherence to PepsiCo Maintenance Management guidelines
• Ensuring NIL loss in packaging due to non-availability of equipments, spares, lack of preventive and corrective maintenance
• Ensuring statutory and legal compliance.
• Implement safety standards and build safe working culture.
• Implement GMPs and best practices.
• Drive corporate agenda- TPM, Safety, AIB, Productivity, OHS.

Responsibilities:Roles and ResponsibilitySafety

• Implement safety standards and drive safety culture.
• Participate in safety meetings and close the agreed recommendations within agreed timeline.
• Work with SHE pillar and safety coordinator on implementing the Safety related action points and working to ensure Zero LTA in the plant.
• Execute safety and sustainability capex and initiatives.

Sustainability

• Track, monitor and report sustainability KPIs.- EUR and WUR
• Drive sustainability agenda and take essential steps to achieve goals.
• Drive new sustainability project trials through continuous improvement

Operational Excellence

• Ensuring that all 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??
• Obtaining resources for conducting this maintenance
• Raising indents for spare parts required
• Getting indents approved by the Plant GM
• Specifying manpower requirements for maintenance jobs to the Sr Engg Officer and coordinating with him about the same
• Interacting with the contractors for getting 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 have to be carried out for the machines
• 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.
• Monitoring the maintenance activities on regular maintenance days (Saturday of every week)
• Reviewing 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 packing machines:
• Replacing carriage assembly moving parts (which are directly involved in bag sealing) with the new parts
• Raising RAR (R&M Appropriation Request) for the approval of Director Operations
• Planning for shutting down the machine for agreed days
• Arranging required spare parts with the Plant Managers approval
• Supervising the fitter and electrician who carry out the actual overhauling

• Maintaining history sheets of overhauling and preventive maintenance schedules

• Ensuring that the engineering stores carries the optimum amount of inventory at all times

• Submitting ABC analysis of spares
• Specifying in consultation with the engineering stores incharge, 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 in order to achieve standardization of purchase rates

• Substituting the defective spare parts in the packaging area with indigenously developed spare parts in order to achieve cost optimization

• Monitoring the utilization of the annual budget
• Developing and sourcing indigenous spare parts to replace defective imported spare parts
• Sourcing of vendors
• Assessing the service capability of the vendors
• Testing the defective part to get material description and supplying the same to the vendor
• Testing the prototype received from the vendor on the machine
• Getting quotations from the suppliers
• Conducting preliminary negotiations with the suppliers on the rates of the part
• Raising indent for the spare part if the tests approve it
• Getting indents approved

• 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.
• liaisoning with the Weights and Measures Department to fix their visits to the plant
• Maintaining all the documents needed for the Weights and Measures Department visit

• Carrying out instrumentation for packaging machines

• Carrying out upkeep, maintenance & calibration of instruments fitted in packing machines. It includes PLCs, temp. controllers, sensors, AC drives, DC drives, Servo drives & Stepper motor drives etc.
• Undertaking certain up gradation activities
• Calibrating the temperature controllers annually
• Engaging an external programmer for PLC programming

• Conducting improvement activities for the packaging machines in order to ensure a machine efficiency of more than 85% at all times
• Guiding the technicians for carrying out various improvement activities so that there are minimum cases of air leakage or film wastage; for example installation of PID temperature controllers to keep the temperature variation limited to +/- 10 C

Planned maintenance

• Preparing maintenance schedule for utility equipment- Boiler, ETP, Bio-methanation, WTP, Electrical distribution system.
• Plan resources to execute PM and share PM Compliance report monthly basis.
• Coordinate and align cross functional team for shutdown, Preventive and other maintenance jobs.
• Address red tags and plan for closure of red tags. Share monthly closure report.
• Prepare root cause analysis for failure and action planning.
• Identify bottlenecks and make action plan.
• Conduct AMC services as per plan and maintain documents.
• Maintain PM related documents- History card, check sheets, service reports, service contracts, agreements.
• Ensure proper utilization of resources.

R&M

• Prepare R&M budget for utilities.
• Monitor and control R&M, share monthly report.
• Drive initiatives for cost saving through local development/procurement, alternate cost effective spares/ systems.
• Proactively highlight R&M expenses event basis.

VMOH

• Prepare AOP for power and fuel usage, R&M, Contractual Manpower deputation and optimization.
• Track and monitor power and fuel usage.
• Reporting power and fuel usage on daily basis.
• Preparing MIS on daily basis and ensure weekly submission to stores and commercial.
• Drive and implement Power and fuel saving initiatives and Kaizen.

Spare Management

• Define inventory level of spares and ensure availability of spares. Classification of spares w.r.t cost and criticality.
• Negotiate with vendors, suppliers, and service providers.
• Control stores inventory.
• Work closely with vendors on high cost / import substitute Spare parts development.
• Conceive, suggest and implement ideas regarding design and modification of existing equipment/spares for improved benefit.
• Support engineering stores in reducing inventory through analysis and acting on non-moving items

TPM

• Drive TPM Agenda.
• 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
• Closely monitor the circle targets and driving the PM pillar action plan

Quality

• Support plant team in driving quality related initiatives- AIB, FSSA, etc.
• Close quality and food safety related observations raised by plant.
• Identifying areas of improvement and highlighting these to Quality Manager
• Implementing the action plans developed by the Quality Manager for continuous improvement.

People management

• Preparing shift schedule.
• Allocating resources, manpower based on the skill and competency.
• Conducting skill assessment for operatives, identify area of improvement.
• Conducting in-house /OEM technical trainings for technicians.
• Developing technicians through involving in projects and other initiatives.
• Conduct daily meeting addressing maintenance related issues and deriving action plan.
• Conduct a meeting with technician sharing engineering performance.

Project Management:

• Execute plant capex as per timeline and approved budget
• Preparing detailed project schedule & tracking the progress
• Selecting the best vendor after complete detailing & techno commercial analysis and getting it approved from commercial
• Ensuring and implementing Safe working practices during the entire project.
• Working with the plant team in designing & implementing proper food safety & hygiene standards for the projects
• Coordinate with cross functional team for seamless execution.
• Work closely with commercial & HR team to get the statutory compliances done for the project.
• Handover of the complete system with proper documentation to the plant team.
• Ensure the Purchase Order closure thru proper verification of job and the amount billed.

Statutory Compliances

• Prepare statutory calendar and ensure implementation.
• Electricity act, The Air (Prevention and Control of Pollution) Act, The Legal Metrology Act, The Explosives Act, The Petroleum Act, The Water (Prevention and Control of Pollution) Act, The Indian Boilers Act, The Factories Act,
• Conduct annual testing and certification of boilers as per IBR norms.

Learning

• Seeking feedback from seniors and peers
• Reflecting on own competencies and possible gaps
• Setting learning goals in consultation with seniors
• Monitoring implementation of these goals
• Continuously updating knowledge from outside environment
• Develop in-depth understanding of MIS, VMOH, MOR etc.

Qualifications:QualificationsBE/BTech in Mechanical / Electrical / Electronics / Electronics and Instrumentation with minimum 6-8 years of experience in a FMCG / Food industry desirable.

• Sound knowledge of Packaging equipment.
• Knowledge about PLC & Process Automation .
• Improvement projects experience.
• Knowledge of Utilities HVAC, DG sets, Air Compressors, Nitrogen Generation Plant, ETP and High pressure Boilers.
• Good Communication and negotiation skills

PepsiCo