Subros Ltd Hiring – Sr. Engineer -Engineer

Subros Ltd Hiring – Sr. Engineer / Engineer (Maintenance Department)

Location: Chennai (Plant)
Experience Required: 4 to 10 Years
Qualification: Diploma / BE
Department: Maintenance

Subros Ltd Hiring, Subros Ltd, a leading name in automotive air-conditioning systems and thermal products, is looking for experienced and skilled professionals for the role of Sr. Engineer / Engineer – Maintenance. This is an excellent opportunity for candidates with strong technical expertise in machine maintenance, automation, and industrial systems.

🔧 Job Overview

Selected candidates will be responsible for ensuring machine uptime, handling preventive and breakdown maintenance, working on automation systems, and supporting plant operations with technical improvements.

🛠 Key Responsibilities

1. Machine Maintenance

   • Responsible for preventive & breakdown maintenance of production machinery.

   • Ensure minimal downtime and perform root-cause analysis.

2. PLC & HMI Programming

   • Hands-on experience in troubleshooting & programming PLCs.

   • Knowledge of HMI interface operations and modifications.

3. Pneumatics & Hydraulics

   • Solid understanding of pneumatic and hydraulic circuits.

   • Ability to troubleshoot related system issues.

4. Basic Automation Skills

   • Exposure to basic industrial automation.

   • Ability to support automation upgrades and improvements.

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🎓 Eligibility Criteria

• Qualification: Diploma or BE in Mechanical / Electrical / Electronics / Mechatronics.
• Experience: 4–10 years in maintenance (automotive or manufacturing preferred).
• Skills Required: Machine maintenance, PLC/HMI, pneumatics, hydraulics, automation basics.

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📩 How to Apply

Send your updated resume to the following email IDs:

• recruitment.chennai@subros.com
• rajitha.nagabandi@subros.com

Top Interview Questions & Detailed Answers

1. Can you explain your experience with preventive and breakdown maintenance?

Answer:

I follow a structured maintenance approach that includes:

• Preparing a preventive maintenance plan based on OEM guidelines
• Conducting daily, weekly, and monthly inspections
• Identifying early signs of wear, overheating, vibration, or abnormal noise
• Maintaining spare parts inventory
• For breakdowns, I perform root-cause analysis using tools like 5 Why, Ishikawa Diagram, and prepare a corrective action plan
• Maintain MTTR/MTBF improvement logs

This helps in reducing downtime and improving machine availability.

2. What PLC brands are you familiar with and what programming tasks have you handled?

Answer:

I have hands-on experience with PLCs such as Siemens, Mitsubishi, Allen-Bradley, and Omron.
Tasks I handled include:

• Ladder logic creation and troubleshooting
• IO mapping and addressing
• Modifying sequences as per production requirements
• Fault diagnosis using PLC diagnostic tools
• Integration with sensors, motors, VFDs, and conveyors

I can also handle online/offline programming and communication protocols like Modbus and Profibus.

3. What is your experience with HMI systems?

Answer:

I have worked with HMIs such as Siemens TP series, Mitsubishi GOT series, and Delta.
Key tasks:

• Designing and modifying HMI screens
• Linking PLC tags with HMI objects
• Trend screens, alarms, and recipe management
• Troubleshooting communication failures between PLC-HMI

4. Explain a major breakdown you handled and how you resolved it.

Answer:

At my previous employer, a key hydraulic press experienced a sudden pressure loss.
I performed:

1. Pressure test to detect leakage
2. Checked solenoid valve, pump, and accumulator
3. Identified internal leakage in directional control valve
4. Replaced valve and flushed the hydraulic line
5. Conducted trial and ensured machine pressure stability

This reduced downtime and prevented repeat failures.

5. What is your experience with pneumatics and hydraulics?

Answer:

I can:

• Read pneumatic and hydraulic circuit diagrams
• Troubleshoot pressure variations, leakage, and actuator failures
• Maintain compressors, FRLs, valves, and cylinders
• Set pressure, flow, and direction control valves
• Conduct preventive maintenance checks

6. How do you ensure safety during machine maintenance?

Answer:

I strictly follow:

• LOTO (Lockout–Tagout)
• Ensuring all power sources are isolated
• Wearing PPE
• Following maintenance SOPs
• Using calibrated tools
• Conducting no-load trial before handing over to production

Safety is always the first priority.

7. Describe your experience with automation.

Answer:

I have worked with:

• Sensors (proximity, photoelectric, temperature)
• VFD programming
• Robot interfacing basics
• Small automation improvements such as pick-and-place systems
• SCADA/monitoring setup

I can design small automation using PLC + HMI to improve productivity.

8. What steps do you take during a machine breakdown?

Answer:

1. Ensure safety and isolate machine
2. Gather information from the operator
3. Diagnose visually and using tools
4. Check PLC logic and sensor conditions
5. Repair/replace faulty parts
6. Run trials and confirm stability
7. Document breakdown report

This ensures quick recovery and proper tracking.

9. How do you manage spare parts inventory?

Answer:

I maintain a proper inventory list including:

• Critical spares
• Minimum and maximum stock levels
• Supplier lead time
• Monthly consumption report

This helps avoid sudden breakdown delays.

10. Why do you want to work at Subros?

Answer:

Subros is a leading manufacturer in the automotive thermal management domain. The company is known for advanced manufacturing systems, world-class machines, and continuous improvement culture.
I believe my skills in machine maintenance, PLC troubleshooting, hydraulics, pneumatics, and automation will add value to Subros operations, and this role gives me an opportunity to grow technically and professionally.

11. What tools or methods do you use for root cause analysis?

Answer:

I use multiple RCA tools depending on the type of breakdown:

• 5 Why Analysis – to find root cause quickly
• Ishikawa (Fishbone) Diagram – for complex recurring issues
• Why-Why sheet – for documenting breakdowns
• FTA (Fault Tree Analysis) – for critical equipment
• Historical breakdown data analysis

This ensures we don’t just fix the symptom but eliminate the root cause.

12. How do you maintain MTTR and MTBF standards?

Answer:

• MTTR (Mean Time to Repair): Reduced by creating SOPs, quick diagnosis, and keeping essential spares ready.

• MTBF (Mean Time Between Failures): Improved through preventive maintenance, condition monitoring, and replacing worn components before failure.

I maintain Excel/CMMS logs to track improvements mnthly.

13. What is your approach to PLC communication troubleshooting?

Answer:

I check:

1. Physical connections (cables, ports, loose wiring)
2. Communication protocols (Ethernet, Modbus, Profibus)
3. IP settings (if Ethernet)
4. PLC communication diagnostics window
5. HMI/SCADA tag communication
6. Replace faulty modules or check power supply

These steps solve 90% of communication failures.

14. Have you worked with VFDs? What types of issues have you solved?

Answer:

Yes, I have experience with Delta, Siemens, ABB, Mitsubishi VFDs.
Common issues I handled:

• Overload trips
• Overcurrent protection
• Motor heating
• Incorrect parameter settings
• PID tuning
• Communication loss
• Speed control malfunction

I also handle parameter backup and installation of new VFDs.

15. What safety standards do you follow in a manufacturing plant?

Answer:

I follow:

• LOTO (Lock Out – Tag Out)
• Permit-to-Work system
• Hazard identification & risk assessment (HIRA)
• PPE & Machine guarding standards
• Electrical safety standards (IS/IEC)
• Fire safety protocols

Safety is integrated into my daily maintenance tasks.

16. What is your experience with CMMS or maintenance software?

Answer:

I have used:

• SAP PM module
• MP2
• Infor EAM
• Tally-based maintenance logs
• Excel-based PM schedules

Using CMMS helps track breakdowns, spares, PM schedules, and machine downtime reports.

17. How do you handle repeated machine failures?

Answer:

1. Analyze breakdown history
2. Perform RCA
3. Check for operator misuse
4. Review sensor alignment and wiring
5. Verify lubrication and wear conditions
6. Replace weak components
7. Update maintenance plan
8. Educate operator if needed

I focus on eliminating repetitive failures permanently.

18. Explain your experience with hydraulics trouble-shooting.

Answer:

I check:

• Hydraulic pressure
• Oil condition (temperature, viscosity, contamination)
• Pump health
• Leakage (internal & external)
• Valve malfunction
• Actuator movement
• Accumulator functioning

Most hydraulic issues arise due to oil contamination or valve blockage.

19. How do you support production during high-demand periods?

Answer:

• Increase frequency of preventive checks
• Keep high-critical spares ready
• Maintain quick-response team
• Conduct daily coordination with production
• Monitor machine parameters closely
• Implement predictive maintenance where possible

This ensures uninterrupted production.

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20. Subros Ltd Hiring How do you plan to contribute to Subros if selected?

Answer:

I will contribute by:

• Improving machine uptime through proper PM
• Applying automation skills to enhance productivity
• Reducing breakdowns using RCA
• Ensuring safety compliance
• Optimizing spare parts consumption
• Supporting continuous improvement (Kaizen) activities

My goal is to reduce downtime and increase machine efficiency.