Asst. Manager: Maintenance - Body PU

Responsibilities & Key Deliverables

• Manage and optimise the operation of Fanuc Robots utilised in various applications such as spot welding, material handling, CO2 welding, and hemming, ensuring high precision and efficiency.
• Develop, test, and implement robot programming, while diagnosing and resolving issues related to robot controllers to minimise downtime and maintain production flow.
• Address and resolve challenges associated with robot periphery and integration, including robotic grippers and associated tooling systems.
• Lead initiatives for robotic cycle time optimisation to improve throughput and operational performance.
• Oversee maintenance and troubleshooting of a wide range of body shop equipment, including adaptive welding controllers (BOSCH), robotic servo guns (OBARA), and conveyor and material handling systems (WEVIN/ATS).
• Maintain and repair manual spot-welding guns (NASH), electro-pneumatic fixtures and their components, CO2 welding machines (ESAB, FRONIUS), manual sealer systems, DC tools, and pneumatic and hydraulic systems to ensure all equipment meets safety and performance standards.
• Maintain ancillary equipment such as air balancers, spring balancers, slat conveyors, overhead hoists, ensuring reliability and safety in the body production line.
• Implement and manage the TPM (Total Productive Maintenance) system, including planned maintenance (PM), time-based maintenance (TBM), and condition-based maintenance (CBM) strategies to maximise equipment availability.
• Utilise PLCs for control systems, with expertise in Mitsubishi MELSEC IQ-R and Siemens S7-300/S7-1500 series for programming, commissioning, and troubleshooting to support automation processes.
• Work closely with cross-functional teams to facilitate smooth integration of robotic and automated systems within the manufacturing environment, continuously seeking improvements aligned with lean manufacturing principles.
• Ensure compliance with health, safety, and environmental standards related to robotic and automated equipment operation and maintenance.
• Support training and development initiatives to upskill team members on robot programming, system troubleshooting, and preventive maintenance.

Preferred Industries

Education Qualification

Applicants should possess a relevant engineering qualification to qualify for this role. Specifically, a Bachelor of Engineering (BE) or Bachelor of Technology (B.Tech) degree specialising in Electrical, Electronics, or Mechatronics engineering is preferred. Alternative equivalent diplomas in these fields may also be considered.

The educational background should equip candidates with foundational knowledge of automation systems, control theory, and robotics, enabling effective handling of complex manufacturing equipment.

Additional certifications in PLC programming, robotic systems, or industrial automation would be considered advantageous and support ongoing professional development within the manufacturing and automotive domains.

General Experience

The ideal candidate will have hands-on experience ranging from 2 to 8 years within a manufacturing environment, preferably within the automobile or auto component industry. This experience should encompass practical involvement in robotic applications, equipment maintenance, and automation process support.

Exposure to diverse production systems and familiarity with body shop manufacturing processes will be highly beneficial. Candidates should demonstrate a strong capability in troubleshooting, preventive maintenance, and cycle time optimisation of robotic and automation machinery.

Experience collaborating within cross-disciplinary teams and participating in continuous improvement initiatives such as TPM or lean manufacturing is important to excel in this role.

Critical Experience

• Extensive expertise in robotic applications with a focus on Fanuc robots, including programming, cycle time optimisation, and troubleshooting of spot welding, CO2 welding, and material handling systems.
• Proficient in the maintenance and repair of critical body shop equipment such as BOSCH adaptive welding controllers, OBARA robotic servo guns, WEVIN and ATS conveyor systems, and associated pneumatic and hydraulic fixtures.
• Advanced skills in PLC programming and troubleshooting, with proven experience in Mitsubishi MELSEC IQ-R and Siemens S7-300/S7-1500 series platforms, including HMIs and VFDs.
• Practical knowledge of Festo CPX series pneumatic control systems, including installation, maintenance, and diagnostics of electro-pneumatic fixtures.
• Demonstrated ability to implement and operate TPM strategies effectively, including PM, TBM, and CBM, to increase operational efficiency and equipment reliability.
• Strong problem-solving skills with the aptitude to swiftly diagnose and rectify robot controller faults and integration concerns affecting production-line automation.
• Experience working within automotive manufacturing or related industrial sectors that require adherence to stringent safety and quality standards.
• Proven track record of leading continuous improvement efforts, driving innovation in automation, and contributing to operational excellence within manufacturing processes.

System Generated Core Skills

System Generated Secondary Skills