Sr Maintenance Engineer at Mattel in Dongguan

Job description

Key Responsibilities Take charge of difficult and recurring equipment breakdown troubleshooting for injection molding machines, auxiliary units, ultrasonic welders, robotic stations, conveyors, decorating machines, automated packaging equipment and peripheral utilities on Barbie production lines. Conduct root cause analysis and implement permanent countermeasures. Lead the deployment, execution and continuous optimization of TPM / Preventive Maintenance (PM) and Predictive Maintenance plans; formulate maintenance work instructions, checklists, lubrication schedules and overhaul standards. Manage spare parts: classify critical spare parts, set safety stock level, review consumption data, optimize inventory, reduce emergency procurement cost while supporting quick repair response. Carry out minor modification, retrofit and reliability upgrade of existing equipment to fix design defects, reduce failure frequency and improve maintainability, under Mattel EH&S and safety review rules. Ensure all maintenance activities strictly follow LOTO, machine guarding, functional safety and Mattel global safety standards; organize risk assessment for overhaul, modification and special maintenance work. Track maintenance KPIs including MTBF, MTTR, downtime rate, maintenance cost and OEE; compile failure records, maintenance logs, monthly reliability review reports and share lesson learned. Train and mentor maintenance technicians, organize skill sharing, standardize troubleshooting methods, improve the overall repair capability of the maintenance team. Cooperate with automation and equipment engineers in new machine SAT, commissioning and acceptance; hand over maintenance know-how, prepare maintenance manual and backup files for new production lines for Barbie NPI projects. Communicate with equipment vendors for technical support, component repair and failure analysis; prepare relevant technical documents in English when required.   Requirements Education & Experience Bachelor degree or above in Mechatronics, Mechanical, Electrical, Automation or related discipline; college diploma with rich relevant experience is also acceptable Minimum 5 years hands-on maintenance experience in high-volume plastic, consumer goods or toy manufacturing plant Familiar with injection molding and automated assembly/packaging line maintenance; multinational factory experience is preferred Technical Competencies Solid knowledge in mechanical structure, hydraulic & pneumatic system, electrical control circuit, PLC, servo, sensors and safety interlock Hands-on troubleshooting experience for industrial robots, vision systems and decorating equipment is a plus Able to read mechanical drawings and electrical schematics independently Familiar with TPM, 5-Why, 8D root cause analysis and maintenance management process Understand FAT/SAT, LOTO and machine safety requirements Soft Skills & Language Basic to intermediate business English for reading manuals and simple vendor communication Strong on-site hands-on capability, calm when facing urgent breakdowns Safety-first mindset, good teamwork, patient in coaching technicians Result-oriented, good at summarizing failure experience and standardizing maintenance practices