Mechanical Maintenance - Level III

 Key Responsibilities A. Machine Maintenance

      A. Machine Maintenance

• CNC machines (VMC, HMC, Turning Centers)
• Conventional machines (lathe, milling, grinding)
• Special purpose machines (SPMs)
• Transfer lines / assembly-linked equipment
• Check and maintain:
  • Spindle systems
  • Ball screws & linear guides
  • Automatic tool changers (ATC)
  • Hydraulic & pneumatic systems

B. Preventive & Predictive Maintenance

• Execute PM schedule for all machines
• Perform:
  • Lubrication audits
  • Backlash & alignment checks
  • Vibration & temperature monitoring
  • Coolant system maintenance
• Ensure 100% PM compliance

C. Breakdown Maintenance

• Attend machine breakdowns with fast response time
• Diagnose faults (mechanical, hydraulic, basic PLC interface support)
• Reduce MTTR (Mean Time to Repair)
• Implement RCA & CAPA to avoid recurrence

D. Accuracy & Quality Support

• Ensure:
  • Machine geometry accuracy
  • Dimensional consistency of output
• Support:
  • Trial runs after maintenance
  • Root cause analysis for rejection due to machine issues

E. TPM & Continuous Improvement

• Drive:
  • Autonomous Maintenance (JH pillars)
  • Kaizen projects
• Focus on:
  • Breakdown reduction
  • OEE improvement
  • Setup time reduction

F. Safety & Compliance

• Strictly follow:
  • LOTO procedures
  • Work Permit system
  • Machine safety standards
• Ensure:
  • Guarding & interlocks functionality
  • Safe practices during maintenance

G. Documentation & CMMS

• Update:
  • Breakdown history
  • PM checklists
  • Spare consumption
• Use CMMS (e.g., IBM Maximo) for:
  • Work orders
  • Asset tracking

H. Spare & Inventory Support

• Identify critical spares:
  • Bearings, seals, belts, filters
  • Hydraulic components
• Support:
  • Inventory control
  • Vendor coordination

3. Key Performance Indicators (KPIs)

• Machine uptime: > 95–98%
• PM compliance: > 95%
• MTTR reduction
• Breakdown frequency reduction
• OEE improvement (%)
• Rejection due to machine issues (↓)
• Safety incidents: Zero