JSM Machine Shop Maintenance- Controls

JSM Machine Shop Maintenance- Controls

Phaltan, Maharashtra, India

JOB DESCRIPTION

Job Summary

The Controls & Electrical Maintenance Engineer is responsible for troubleshooting, maintaining, repairing, and continuously improving electrical, control, CNC, PLC, automation, hydraulic, and pneumatic systems to ensure safe, reliable, and efficient manufacturing operations. This role supports equipment uptime, preventive and predictive maintenance programs, root cause analysis, machine reliability initiatives, and operational excellence. The incumbent works independently on complex issues while also coaching and supporting less experienced team members, ensuring compliance with Cummins safety, quality, and maintenance standards.

Key Responsibilities

Health, Safety & Environmental (HSE)

Champion a strong safety culture by adhering to all Cummins HSE policies, procedures, and regulatory requirements.

Immediately stop work and report unsafe conditions, incidents, injuries, or hazards.

Follow machine safety standards, Lockout/Tagout (LOTO) procedures, and electrical safety requirements.

Utilize appropriate Personal Protective Equipment (PPE) and promote safe work practices.

Identify and mitigate hazards associated with electrical, hydraulic, pneumatic, and automated systems.

Participate in HSE training and contribute to an injury-free workplace culture.

Equipment Maintenance & Reliability

Troubleshoot and repair electrical, PLC, CNC, automation, hydraulic, and pneumatic system failures.

Perform preventive, predictive, corrective, and breakdown maintenance activities to maximize equipment availability and reliability.

Support CNC machines, Special Purpose Machines (SPMs), robotic cells, conveyors, nut runners, and automated production equipment.

Diagnose and resolve issues related to PLCs, HMIs, CNC controls, servo systems, spindle drives, sensors, motion control systems, and industrial communication networks.

Conduct panel-level troubleshooting, electrical modifications, system commissioning, and component replacements.

Analyze recurring equipment failures and implement effective corrective and preventive actions.

Support TPM, predictive maintenance, condition monitoring, MTTR reduction, and MTBF improvement initiatives.

Controls & Automation

Support, modify, and optimize PLC programs, HMI applications, and machine control systems.

Implement automation improvements that enhance productivity, quality, safety, and process efficiency.

Support MES, OEE monitoring systems, and Industry 4.0 initiatives where applicable.

Assist with machine upgrades, automation projects, and integration of new technologies into manufacturing systems.

Develop and implement machine programming solutions to improve machine utilization and overall performance.

Quality & Continuous Improvement

Execute maintenance activities in accordance with electrical drawings, technical documentation, operating manuals, and specifications.

Apply high standards of workmanship and craftsmanship during all maintenance activities.

Support equipment downtime analysis and root cause investigations.

Perform quality inspections and ensure adherence to established quality standards.

Identify opportunities for cost reduction, energy efficiency, process optimization, and waste elimination.

Provide feedback into preventive maintenance systems and support continuous improvement projects.

Planning & Documentation

Maintain accurate maintenance records, preventive maintenance documentation, breakdown reports, and spare parts usage in CMMS systems such as MAXIMO.

Support spare parts planning and inventory management activities.

Coordinate with OEMs, contractors, and vendors for specialized maintenance support and equipment upgrades.

Schedule maintenance activities to minimize impact on production requirements.

Teamwork & Collaboration

Work closely with Production, Engineering, Quality, Maintenance, and Operational teams to resolve equipment issues.

Act as a technical resource and provide guidance, coaching, and knowledge sharing to team members.

Participate actively in Total Productive Maintenance (TPM) and continuous improvement teams.

Complete required training and actively engage in personal and professional development activities.

Communicate effectively across functions to support business objectives and operational excellence.

EXTERNAL QUALIFICATIONS AND COMPETENCIES

Qualifications

Education

Diploma in Electrical, Electronics, Industrial Automation, Mechatronics, or a related technical discipline.

High School Diploma/Secondary Education certificate may be considered where supplemented by significant relevant experience and applicable technical qualifications.

Certifications in PLC Programming, Industrial Automation, CNC Systems, Robotics, Electrical Maintenance, or related areas are preferred.

Additional Requirements

May require licensing or authorization for compliance with export control or sanctions regulations, where applicable.

Skills

Technical Skills

Electrical Maintenance & Troubleshooting

PLC Programming & Industrial Automation

CNC Controls & Diagnostics

HMI & SCADA Systems

Factory Automation & Control Systems

Machine Programming

Servo Drives, Spindle Drives & Motion Control Systems

Electrical Drawings, Schematics & Control Panels

Industrial Communication Networks (Profinet, Profibus, Ethernet/IP)

Hydraulic & Pneumatic Systems

Robotics & Automated Material Handling Systems

MES, OEE Monitoring & Industry 4.0 Technologies

CMMS/MAXIMO Applications

Predictive Maintenance & Condition Monitoring

Root Cause Analysis & Reliability Engineering

TPM (Total Productive Maintenance)

Competencies

Collaborates

Communicates Effectively

Customer Focus

Decision Quality

Drives Results

Nimble Learning

Values Differences

Health & Safety Fundamentals

Controls Safety

Electrical System Troubleshooting

Manufacturing Knowledge

Continuous Improvement Mindset

Problem Solving & Analytical Thinking

Coaching and Knowledge Sharing

ADDITIONAL RESPONSIBILITIES UNIQUE TO T