Maintenance Engineer

Minimum Requirements

• Education:
  • Bachelor’s Degree in Mechatronics, Robotics, Electromechanical, Electrical, Electronics, Mechanical Engineering, or related technical field.
• Work Experience:
  • 2+ years of experience in the automotive manufacturing industry with direct involvement in industrial maintenance, automation, controls, instrumentation, and shop-floor equipment troubleshooting.
  • 2+ years of experience implementing reliability and maintainability systems (TPM, RCM).
  • Demonstrated experience leading and managing hourly technical personnel within unionized manufacturing environments.
• Technical Skills & Systems:
  • Proven hands-on knowledge of industrial automation hardware and software platforms: Siemens (TIA Portal, STEP 7, WinCC, Sinamics, Sinumerik), Allen-Bradley / Rockwell Automation.
  • Working knowledge of industrial robotics: FANUC and/or ABB (electrical and mechanical troubleshooting, programming, and point teaching).
  • Solid understanding of electrification lines and equipment: electric motors, drives, industrial electronics, power transformers, and battery assembly processes.
  • Experience with CMMS platforms, specifically Maximo (work order creation, PM/AM execution, asset tracking).
  • Incident investigation methodologies (e.g., 4D, 8D, Root Cause Analysis, OSHIM/GPA).
• Work Conditions:
  • Availability to rotate shifts and support line shutdowns / planned maintenance windows.
• Language:
  • Professional Working English (written and spoken) to collaborate with global engineering teams and vendors.

Position Duties & Responsibilities

1. Safety (Zero Injuries - 0/100 Philosophy)

• Enforce and lead plant safety standards; review and approve Job Safety Analyses (AST/JSA), Verified Journey Plans (VJP), and Pre-Task Analyses (PTA).
• Lead incident/accident investigations using corporate safety tools (OSHIM - GPA).
• Actively manage Energy Control and Power Lockout (ECPL) procedures across automated cells.

2. Quality & Engineering Standards

• Direct maintenance and controls activities to improve line quality metrics (First Time Through - FTT, scrap reduction, contamination control).
• Ensure machine monitoring systems communicate reliably with quality and traceability architectures (FIS, QLS, IIOT).
• Review and approve technical drawings and integration standards for new tooling, equipment, and machinery acceptance.
• Authorize, document, and execute controls/programming modifications via engineering change procedures (CCR / MTC).

3. Delivery & Plant Operations (Constraint & Asset Reliability)

• Drive the 0/100 operational standard (0 injuries, 0 defects, 100% flow/throughput: Constraint, JPH, BTS, and Production Counts).
• Lead root-cause breakdown investigations using the 4D methodology for controls/maintenance downtime exceeding 30 minutes (utilizing FORI / MFM tools).
• Coordinate and execute Planned Maintenance (PM) and Autonomous Maintenance (AM) routines in Maximo.
• Prepare and lead the Constraint Package / MOS Board analysis (TTP, availability, MTTR, MTBF, and line stoppage trends).
• Lead the implementation and execution of the FRACAS (Failure Reporting, Analysis, and Corrective Action System) reliability cycle.
• Maintain up-to-date offline/online program backups and system restore points using AutoSave or enterprise repositories.

4. Cost & Budget Control

• Monitor, control, and reduce MCPU (Maintenance Cost Per Unit) by documenting 100% of planned and unplanned maintenance interventions in Maximo.
• Collaborate with the Maintenance Coordinator to oversee departmental budgets, spare parts consumption, and purchase orders.
• Optimize crib inventory by managing critical spare parts, safety stock, and reaction plans (BBQ / Back-to-Back controls readiness).

5. People, Team Leadership & Union Relations

• Lead, inspire, and develop hourly maintenance technicians; manage technical certification matrices (Task Certification).
• Manage administrative attendance records via DROT / PeopleSoft (attendance, vacations, tardiness, overtime, and time-off tracking).
• Administer e-File records (promotions, leveling, disciplinary procedures, and labor dispute follow-up) in compliance with the Collective Bargaining Agreement (CCT) and the Authority & Responsibility Guidebook (LAR).
• Host regular "Hourly Connection" shift meetings to promote employee engagement, recognition, and safety briefings.
• Lead continuous improvement initiatives (Kaizen, employee suggestion schemes).

Preferred Requirements

• Advanced Degree: Master’s Degree in Mechatronics, Automation, Engineering Management, or an MBA.
• Ford Specific Knowledge:
  • Direct experience with Ford Controls Standard (FAST).
  • Hands-on proficiency with Ford platforms: Maximo for Maintenance & SFR, FIS, QLS, IIOT, DROT, and TeamCenter/FEDE.
• Advanced Vision & Networks:
  • In-depth expertise in industrial vision systems (Cognex, Keyence) and complex industrial networks/gateways (PROFINET, Ethernet/IP, IO-Link).
• Continuous Improvement & Methodologies:
  • Six Sigma Black Belt or Green Belt certification.
  • Experience with Additive Manufacturing (3D printing for tooling/fixtures), Strategic Data Analytics (Minitab), and Lean Manufacturing / MOS.
• Cybersecurity:
  • Knowledge of operational technology (OT) network cybersecurity and industrial OS patch management.
• Language:
  • Advanced / Fluent English (C1 level) for seamless technical negotiation with OEM machinery builders and external integrators (Siemens, WMA, 2nd Tier suppliers).

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