Production & Maintenance Engineer

Job Description: Production & Maintenance Engineer Industry: Disposable Lighter Manufacturing Department: Production, Maintenance & Quality Control Job Location: Ghaziabad, India Employment Type: Full-Time Experience: 3–7 years preferred in manufacturing, plastic injection moulding, assembly lines, or mechanical maintenance. 1. Job Summary We are looking for a technically skilled and responsible Production & Maintenance Engineer to manage daily factory production, machine maintenance, workforce performance, and quality control in our disposable lighter manufacturing unit. The candidate will be responsible for ensuring smooth machine operations, minimizing downtime and rejection rates, improving production output, managing labour, and achieving daily production targets while maintaining safety standards. 2. Key Responsibilities A. Machine Maintenance & Troubleshooting - Handle preventive, predictive, and breakdown maintenance of factory machines. - Diagnose machine faults and arrange timely repairs to minimize production losses. - Maintain machine-wise maintenance records, breakdown reports, and repair histories. - Monitor machine performance and identify recurring mechanical, electrical, pneumatic, and hydraulic problems. - Coordinate with technicians, electricians, and external service providers when required. - Ensure the availability of critical spare parts, tools, and maintenance materials. - Conduct regular inspections of motors, sensors, cylinders, conveyors, heaters, pneumatic systems, and other machine components. - Ensure proper maintenance of injection moulding machines, welding machines, assembly machines, gas-filling machines, flame-setting machines, and automatic QC equipment, wherever applicable. B. Production Planning & Management - Prepare daily and hourly production plans according to factory targets and available manpower. - Monitor production output from each machine and production stage. - Identify bottlenecks and improve the flow of materials between different production processes. - Ensure machines and workers are utilized efficiently throughout the shift. - Coordinate with supervisors to meet production targets without compromising product quality. - Monitor work-in-progress, finished goods, material consumption, and production losses. - Take corrective action when hourly production targets are missed. - Prepare daily production reports and submit performance summaries to management. C. Labour & Workforce Management - Allocate workers to machines and production stations according to skill and workload. - Monitor worker attendance, punctuality, discipline, productivity, and work efficiency. - Ensure that sufficient manpower is available at every production stage. - Train workers in standard operating procedures, quality requirements, and safe machine operation. - Balance manpower between departments to prevent production bottlenecks. - Coordinate with supervisors to resolve labour-related operational issues. - Ensure workers follow production schedules, safety rules, and workplace discipline. - Evaluate worker and team performance using measurable production indicators. D. Quality Control & Rejection Reduction - Monitor rejection rates at each production stage. - Investigate recurring defects and implement corrective and preventive actions. - Coordinate with the QC team to identify the root causes of product failures. - Maintain rejection records, inspection reports, and corrective-action logs. - Ensure compliance with approved quality standards and product specifications. - Work to reduce material wastage, rework, and customer complaints. - Stop and escalate unsafe or nonconforming production conditions when necessary. E. Production Data & Reporting - Maintain hourly production and rejection reports for every major machine. - Record machine downtime, reasons for stoppages, and time lost. - Track planned versus actual production. - Monitor machine utilization, labour productivity, rejection percentage, and overall production efficiency. - Maintain preventive maintenance schedules and machine checklists. - Submit daily reports covering production, maintenance, quality, labour, and operational issues. F. Continuous Improvement - Identify opportunities to increase production capacity without unnecessary capital expenditure. - Reduce machine downtime, idle labour, bottlenecks, and recurring defects. - Improve production methods, workstation layouts, and material handling. - Establish standard operating procedures for machines and production activities. - Recommend practical improvements to management based on production data. - Support lean manufacturing, 5S, and continuous improvement initiatives. G. Factory Safety & Compliance - Ensure workers follow machine operating procedures and applicable factory safety requirements. - Maintain machine guards, emergency stops, electrical safety, and preventive maintenance controls. - Ensure proper handling of butane-propane fuel and other flammable materials. - Ensure gas-filling and testing operations follow approved procedures and applicable safety requirements. - Stop unsafe operations and immediately report gas leaks, fire hazards, damaged equipment, or other critical risks. - Maintain relevant maintenance, training, inspection, and safety records. 3. Performance Indicators (KPIs) The engineer will be evaluated on: - Achievement of daily and hourly production targets. - Reduction in machine downtime and breakdown frequency. - Reduction in product rejection and rework rates. - Improvement in labour productivity. - Timely completion of preventive maintenance. - Reduction in material wastage and avoidable production losses. - Accuracy and timely submission of production reports. - Compliance with safety procedures and quality standards. 4. Required Qualifications - Diploma or Bachelor's degree in Mechanical Engineering, Electrical Engineering, Mechatronics, Production Engineering, or a related technical field. - Practical experi