Job Purpose
Ensure the reliable operation and maintenance of automated packaging systems for cards and vehicle license plates. The role covers machine setup, daily operation, troubleshooting, preventive maintenance, and continuous improvement to meet production targets, maintain packaging quality, and ensure accurate matching of each item with its recipient’s information.
Key Responsibilities
- Operate, configure, and monitor automated packaging machines, including feeding, identification, envelope insertion, adhesive sealing, label printing and application, and sorting.
- Perform machine setup and changeovers for different card and vehicle plate sizes, packaging materials, and order types.
- Diagnose and resolve mechanical, electrical, pneumatic, and control system faults to minimize downtime.
- Inspect, adjust, and maintain sensors, motors, servo drives, conveyors, feeders, rollers, pneumatic components, and adhesive application systems.
- Troubleshoot PLC-controlled equipment and HMI alarms, using electrical diagrams, machine manuals, and diagnostic tools.
- Maintain barcode readers, vision systems where fitted, thermal printers, and labeling equipment.
- Maintain, calibrate, and troubleshoot OCR, barcode readers, cameras, lighting, triggers, and related identification components used for item recognition and verification.
- Verify accurate matching between cards or plates, recipient data, shipping labels, and assigned sorting outlets.
- Monitor rejected, unreadable, mismatched, and process-failed items and ensure proper reconciliation between input records, processed items, successfully packaged items, rejected items, and final sorting outputs.
- Monitor and troubleshoot sorting logic, conveyor routing, diverters, sensors, and output lanes to ensure items are directed to the correct destination.
- Coordinate with IT teams and equipment manufacturers to resolve machine communication, data exchange, and software interface issues.
- Control approved machine recipes, parameters, configurations, and software settings, ensure changes are authorized and documented, and maintain approved backups in coordination with IT and equipment manufacturers.
- Develop and execute preventive maintenance schedules in accordance with manufacturer recommendations.
- Record breakdowns, maintenance activities, spare parts usage, and corrective actions; conduct root cause analysis for recurring failures.
- Identify critical spare parts and consumables and coordinate minimum stock requirements to reduce maintenance-related downtime.
- Monitor production throughput, downtime, packaging defects, and rejection rates, and implement improvements.
- Monitor machine availability and identification accuracy against approved operational and acceptance targets, in addition to throughput, downtime, defects, and rejection performance.
- Support installation, commissioning, factory and site acceptance testing, and production readiness activities.
- Participate in performance and stress testing, verify reject handling and functional requirements, and support punch-list closure and final production readiness.
- Train operators on machine operation, changeovers, routine checks, and basic troubleshooting.
- Follow machine safety, energy isolation, information security, and item traceability procedures.
Required Qualifications and Experience
- Bachelor’s degree in Mechatronics, Electrical, Mechanical, Automation Engineering, or a related discipline.
- At least five years of hands-on experience operating and maintaining automated packaging, inserting, mailing, or comparable production equipment.
- Demonstrated experience troubleshooting integrated production lines involving feeding, conveying, sealing, labeling, and sorting.
- Practical knowledge of PLC diagnostics, HMI operation, sensors, motor controls, servo systems, and pneumatics.
- Ability to read electrical diagrams, mechanical drawings, and technical manuals.
- Experience performing preventive maintenance, fault diagnosis, and root cause analysis.
- Good command of technical English and the ability to communicate effectively with equipment manufacturers.
- Willingness to work shifts and respond to operational breakdowns when required.
Preferred Experience
- Automated card, document, passport, or vehicle plate packaging systems.
- Envelope inserting equipment, adhesive sealing systems, and automatic sorting mechanisms.
- Barcode verification, machine vision, thermal label printing, and production data interfaces.
- Hands-on experience with OCR, automated identification, reject handling, reconciliation, and automated sorting systems is preferred.
- Equipment commissioning and manufacturer-led technical training.
Key Competencies
Hands-on troubleshooting, mechanical and electrical aptitude, attention to detail, safety awareness, ownership of equipment reliability, and effective coordination with operations, IT, and suppliers.
Experience Requirement
Direct experience with automated industrial equipment is essential. Office printer, photocopier, or general IT support experience alone does not meet the requirements of this role.
