Job Description: Lead – Automation & Calibration

Job Purpose

Lead automation and calibration activities across the facility to improve equipment reliability, operational efficiency, and productivity while optimizing manpower and maintenance costs. Plan and execute preventive maintenance, calibration activities, and automation improvement projects to ensure the smooth operation of machinery, control systems, and instrumentation. Drive technological improvements, energy conservation, and process synchronization through automation.

Key Responsibilities

1. Automation & Maintenance

• Reduce machine downtime related to automation and electrical systems through effective maintenance and troubleshooting.
• Monitor and analyze equipment conditions, failures, and parameter deviations to implement preventive, predictive, and condition-based maintenance.
• Conduct root cause analysis of recurring equipment failures and implement Corrective and Preventive Actions (CAPA).
• Implement hardware and software modifications to prevent repeated failures and improve equipment reliability.
• Analyze machine logbooks and SCADA data to identify issues and prioritize corrective actions.
• Ensure the availability and readiness of critical spare parts to maintain plant uptime.
• Ensure the smooth operation of automation systems for Gel Room, HCM, PFD, and utility equipment.
• Maintain the proper functioning of PLC, HMI, SCADA, VFD, and servo drive systems, ensuring that operating parameters comply with established standards.
• Coordinate closely with mechanical and electrical maintenance teams to minimize equipment breakdowns.
• Ensure compliance with electrical safety requirements.

2. Calibration & Verification

• Plan and ensure the calibration and verification of all designated equipment according to the approved calibration schedule.
• Maintain calibration and verification documentation, including equipment history cards, calibration certificates, and traceability certificates.
• Ensure compliance with applicable regulatory and statutory requirements.
• Review and maintain systems for monitoring equipment calibration status.
• Develop alternative vendors and conduct risk assessments to mitigate supply-related risks and maintain compliance.

3. Automation Projects & Continuous Improvement

• Plan and execute capacity expansion and equipment improvement projects related to automation.
• Monitor project progress against approved schedules, budgets, and project plans.
• Coordinate with consultants and internal subject matter experts (SMEs) for system design when required.
• Support other departments in implementing their improvement projects.
• Drive automation initiatives to improve productivity, operational efficiency, and process synchronization.

4. Energy Conservation

• Implement energy-saving projects to achieve established Energy Cost Reduction (ECR) targets.
• Monitor, plan, and execute initiatives to reduce energy consumption and operating costs.

5. Cost Optimization

• Reduce spare parts consumption and optimize maintenance-related expenditure.
• Identify cost-effective solutions for automation improvement projects through vendor development.
• Optimize costs associated with calibration and verification activities without compromising compliance.

6. Reporting & Documentation

• Prepare and submit monthly project progress trackers to the Head of Department (HOD).
• Prepare and submit monthly calibration activity review reports.
• Submit monthly Preventive Maintenance (PM) compliance reports.

7. Team Leadership & Development

• Develop team members through cross-training and multi-skilling initiatives.
• Provide on-the-job and classroom training to technicians and associates.
• Coordinate with internal engineering and maintenance teams and external vendors to support effective plant operations.

Key Performance Indicators (KPIs)

• Reduction in machine downtime.
• Improvement in productivity.
• Cost optimization.
• Achievement of Energy Cost Reduction (ECR) targets.
• Completion of improvement projects according to approved plans.
• Completion of equipment calibration and verification according to the established schedule.

Key Technical Competencies

• Preventive and breakdown maintenance.
• Mechanical knowledge and technical problem-solving.
• Automation and control systems.
• Calibration and verification processes.
• Project planning and management.
• Product and process knowledge.
• Continuous improvement and energy conservation.

Key Leadership Competencies

• Entrepreneurial mindset.
• Team building and development.
• Coaching and nurturing team members.
• Cross-functional collaboration and integration.
• Innovation and continuous improvement.
• Stakeholder and vendor relationship management.