Total Productive Maintenance (tpm) Officer

Key Responsibilities and Duties

Total Productive Maintenance (TPM) Implementation:

• Implement and sustain TPM practices across the steel plant.
• Coordinate the eight pillars of TPM, including Autonomous Maintenance, Planned Maintenance, Focused Improvement, Quality Maintenance, Early Equipment Management, Training and Education, Safety, Health and Environment, and Office TPM, as applicable.
• Develop and monitor TPM implementation plans, schedules, and performance targets.
• Promote employee involvement in equipment care and continuous improvement activities.
• Support production and maintenance teams in identifying and eliminating equipment-related losses.
• Conduct regular TPM audits and monitor compliance with established standards.
• Facilitate TPM meetings, equipment improvement teams, and shop-floor improvement activities.

Preventive and Predictive Maintenance:

• Develop, review, and optimize preventive maintenance schedules for mechanical equipment.
• Ensure timely execution of lubrication, inspection, adjustment, cleaning, and component replacement activities.
• Implement predictive maintenance techniques such as vibration analysis, thermography, oil analysis, and condition monitoring.
• Identify equipment deterioration at an early stage and recommend corrective actions.
• Review equipment maintenance history to identify recurring failures and opportunities for improvement.
• Coordinate planned maintenance shutdowns with production and other maintenance departments.
• Ensure maintenance activities are properly documented in the Computerized Maintenance Management System (CMMS), where available.

Mechanical Equipment Reliability and Maintenance:

• Monitor the reliability and performance of critical steel plant equipment, including:
• Rolling mill stands, gearboxes, bearings, and drive systems.
• Steel Melting Shop (SMS) auxiliary mechanical equipment.
• Continuous Casting Machine (CCM) mechanical systems.
• Pumps, compressors, fans, blowers, and hydraulic systems.
• Conveyors, transfer tables, and material-handling systems.
• Industrial cranes and lifting equipment.
• Cooling water systems, lubrication systems, and centralized grease systems.
• Analyze recurring mechanical failures and recommend permanent corrective measures.
• Support troubleshooting and repair of equipment breakdowns.
• Ensure proper alignment, balancing, installation, and commissioning of rotating equipment.
• Monitor equipment wear, vibration, temperature, lubrication condition, and abnormal operating behavior.
• Improve equipment maintainability and reduce unplanned production interruptions.

Autonomous Maintenance:

• Support production operators in carrying out routine equipment inspection, cleaning, lubrication, and tightening activities.
• Develop and implement autonomous maintenance checklists and inspection standards.
• Train operators to identify abnormalities such as oil leaks, loose fasteners, abnormal vibration, overheating, and unusual noise.
• Establish equipment cleaning and inspection standards to prevent deterioration.
• Coordinate with production teams to close abnormalities identified during routine inspections.
• Promote ownership of equipment condition among operators and maintenance personnel.

Root Cause Analysis and Continuous Improvement:

• Conduct root cause analysis (RCA) for major equipment failures and repeated breakdowns.
• Apply problem-solving techniques such as the 5 Whys, Fishbone Diagram, Pareto Analysis, and Failure Mode and Effects Analysis (FMEA).
• Develop and implement corrective and preventive action plans.
• Lead focused improvement projects to eliminate chronic equipment problems.
• Identify opportunities to reduce mechanical losses, maintenance costs, spare-parts consumption, and equipment downtime.
• Apply Kaizen and other continuous improvement methods to improve plant performance.
• Verify the effectiveness of corrective actions through follow-up inspections and performance monitoring.

Spare Parts and Maintenance Planning:

• Identify critical mechanical spare parts and establish appropriate minimum and maximum stock levels.
• Coordinate with stores and procurement teams to ensure the availability of essential maintenance materials.
• Review spare-parts consumption and identify opportunities for standardization and cost reduction.
• Assist in preparing annual maintenance budgets and shutdown maintenance plans.
• Ensure proper technical specifications for replacement parts and mechanical components.
• Support vendor evaluation, equipment selection, and technical discussions where required.

Performance Monitoring and Reporting:

• Monitor key TPM and maintenance performance indicators.
• Prepare daily, weekly, and monthly reports on equipment performance and maintenance activities.
• Track Overall Equipment Effectiveness (OEE), equipment availability, MTBF, MTTR, and breakdown frequency.
• Monitor planned maintenance compliance and outstanding equipment abnormalities.
• Conduct performance reviews and recommend corrective actions where targets are not achieved.
• Maintain equipment history, inspection records, audit reports, and improvement project documentation.

Safety, Health, and Environmental Compliance:

• Ensure all mechanical maintenance activities comply with plant safety procedures.
• Enforce Lockout/Tagout (LOTO), permit-to-work, and equipment isolation procedures.
• Ensure compliance with machine guarding, lifting, rigging, and working-at-height requirements.
• Identify mechanical hazards and implement appropriate risk-control measures.
• Ensure safe maintenance practices around hot metal, rotating machinery, hydraulic systems, and pressurized equipment.
• Participate in safety inspections, incident investigations, and corrective action reviews.
• Promote safe working practices and good housekeeping throughout the plant.

Key Performance Indicators (KPIs)

Performance will be measured using the following indicators:

• Overall Equipment Effectiveness (OEE): Improvement in equipment availability, performance, and quality.
• Mean Time Between Failures (MTBF): Increase in the average operating time between equipment failures.
• Mean Time to Repair (MTTR): Reduction in average equipment repair time.
• Breakdown Frequency: Reduction in unplanned mechanical failures.
• Preventive Maintenance Compliance: Percentage of scheduled maintenance tasks completed on time.
• Planned Maintenance Ratio: Increase in planned maintenance compared with reactive maintenance.
• Maintenance Cost: Reduction in maintenance costs per tonne of steel produced, where measurable.
• TPM Audit Score: Improvement in compliance with TPM standards and implementation plans.
• Autonomous Maintenance Compliance: Percentage of completed operator inspection and equipment care activities.
• Corrective Action Closure: Percentage of RCA and audit action items closed within agreed deadlines.
• Safety Performance: Compliance with safety procedures and reduction in maintenance-related incidents.
• Spare Parts Availability: Improved availability of critical mechanical components.

Qualifications and Experience

• Bachelor's Degree in Mechanical Engineering or an equivalent qualification.
• HND in Mechanical Engineering may be acceptable where supported by relevant industrial experience and company requirements.
• Typically, 3 - 5 years of experience in mechanical maintenance, equipment reliability, or TPM implementation in a steel plant or heavy manufacturing industry.
• Practical knowledge of preventive and predictive maintenance systems.
• Experience in rolling mills, Steel Melting Shops, Continuous Casting Machines, or other steel production equipment is an advantage.
• Knowledge of TPM, Lean Manufacturing, Kaizen, 5S, and continuous improvement methodologies.
• Experience with CMMS or maintenance management software is desirable.
• Relevant training or certification in TPM, reliability engineering, vibration analysis, or maintenance planning is an advantage.

Technical Skills and Competencies:

• Strong knowledge of industrial mechanical systems and rotating equipment.
• Understanding of bearings, gearboxes, couplings, shafts, chains, belts, and lubrication systems.
• Knowledge of hydraulic and pneumatic systems.
• Ability to interpret mechanical drawings, assembly drawings, and equipment manuals.
• Knowledge of vibration monitoring, alignment, balancing, and condition-based maintenance.
• Ability to perform equipment failure analysis and develop corrective action plans.
• Understanding of maintenance planning, scheduling, and shutdown management.
• Proficiency in Microsoft Excel, Word, and maintenance reporting tools.
• Familiarity with OEE, MTBF, MTTR, FMEA, RCA, and Pareto analysis.