Team Member-Instrumentation - Packing Plant

Job Description: E&I Shift In-Charge – Packing Plant, Cement Grinding Unit

Position: E&I Shift In-Charge – Packing Plant
Department: Electrical & Instrumentation / Maintenance
Industry: Cement Manufacturing – Grinding Unit
Reporting To: E&I Manager / Maintenance Head

Job Purpose

Responsible for the safe, reliable, and efficient operation and maintenance of all Electrical & Instrumentation (E&I) systems associated with the cement packing plant. The role involves shift-wise supervision, troubleshooting, preventive maintenance, breakdown handling, manpower management, and ensuring maximum equipment availability with minimum downtime.

Key Responsibilities

• Supervise E&I maintenance activities during the shift in the cement packing plant.
• Ensure reliable operation of:
  • Cement packing machines
  • Bagging machines and electronic packers
  • Bag conveyors and belt conveyors
  • Bucket elevators
  • Vibrating screens and feeders
  • Truck loading systems
  • Automatic loading/unloading systems
  • Compressors and pneumatic systems
  • Dust extraction systems
  • Weighing and bag-counting systems
  • Motors, MCCs, VFDs and control panels
• Attend and troubleshoot electrical breakdowns involving motors, starters, MCCs, VFDs, contactors, relays, sensors and control circuits.
• Troubleshoot instrumentation and automation faults, including:
  • PLC/DCS systems
  • HMI/SCADA
  • Proximity and photoelectric sensors
  • Load cells
  • Pressure, temperature and level transmitters
  • Weighing systems
  • Solenoid valves and pneumatic controls
  • Encoder and speed-feedback systems
• Monitor and maintain packing machine accuracy, bag weight control and automatic control systems.
• Coordinate with production personnel for quick restoration of equipment during breakdowns.
• Execute preventive and predictive maintenance as per maintenance schedules.
• Analyze repeated failures and implement root-cause corrective actions.
• Maintain critical E&I spares and ensure availability of essential components.
• Prepare shift-wise breakdown reports, maintenance logs and equipment status reports.
• Monitor electrical parameters such as current, voltage, power factor, motor loading and VFD status.
• Ensure proper functioning of interlocks, emergency stops, safety switches and protection systems.
• Carry out calibration and functional checks of weighing and instrumentation systems.
• Supervise technicians, electricians and instrument technicians working during the shift.
• Allocate manpower according to breakdown, preventive-maintenance and production requirements.
• Ensure compliance with LOTO/PTW and electrical safety procedures before maintenance work.
• Coordinate with mechanical, production and utility teams during equipment maintenance.
• Participate in shutdown planning and execution of major E&I maintenance activities.
• Maintain records of equipment history, breakdown frequency, MTBF and MTTR.
• Identify opportunities for energy saving, automation improvement and reliability enhancement.
• Ensure housekeeping and 5S standards in electrical/instrumentation areas.

Key Performance Indicators (KPIs)

• Packing plant equipment availability
• Reduction in electrical/instrumentation breakdowns
• MTBF and MTTR
• Preventive-maintenance compliance
• Packing machine uptime
• Packing accuracy and weighing-system reliability
• Response time to breakdowns
• Energy consumption and electrical efficiency
• Safety compliance and zero electrical accidents
• Critical spare availability
• Reduction of repeat failures

Required Qualifications

• Diploma/B.E./B.Tech in Electrical, Electronics & Instrumentation, or related engineering discipline
• Typically 4–8 years of experience in E&I maintenance in cement, grinding, packing, bulk material handling, or similar process industries.
• Experience with PLC, VFD, MCC, instrumentation and industrial automation is preferred.
• Cement-plant/packing-plant experience will be an advantage.

Required Skills

• Strong electrical troubleshooting skills
• Good knowledge of industrial instrumentation
• PLC and HMI troubleshooting
• VFD parameter checking and fault diagnosis
• Knowledge of motors, MCCs and control panels
• Understanding of weighing/load-cell systems
• Knowledge of pneumatic control systems
• Ability to read electrical and instrumentation drawings
• Shift manpower supervision
• Breakdown analysis and RCA
• Preventive-maintenance planning
• Good communication and coordination skills
• Strong focus on safety