DUTIES AND RESPONSIBILITIES

Motor Fault Diagnosis and Assessment

• Conduct thorough inspections of AC/DC motors, alternators, and transformers to identify faults such as winding failures, insulation breakdowns, bearing issues, or mechanical damage.
• Use diagnostic instruments like insulation testers (megohmmeters), multimeters, and motor testers to evaluate motor condition and performance.
• Document findings and recommend appropriate rewinding or repair actions.

Motor Rewinding and Repair

• Carefully disassemble motors, alternators, or transformers, ensuring no damage to parts.
• Remove old winding coils and prepare stator or rotor cores for rewinding by cleaning and checking for any structural damage.
• Measure and calculate the exact winding specifications such as number of turns, wire gauge, coil spacing, and connection points, following manufacturer specifications or engineering drawings.
• Rewind motors by hand or using winding machines, ensuring precision in coil placement and tension to meet performance standards.
• Insulate windings properly with varnishes, tapes, or other insulation materials to ensure durability and safety.
• Reassemble the motor components correctly and test mechanical alignment and balance.

Testing and Quality Assurance

• Perform electrical tests such as continuity, resistance, insulation resistance, surge comparison, and hypo testing to verify winding integrity and motor performance after rewinding.
• Conduct mechanical tests such as vibration analysis and bearing checks to ensure smooth operation.
• Troubleshoot any issues identified during testing and perform rework as necessary to meet quality standards.
• Maintain detailed records of test results, repairs carried out, and materials used for traceability and reporting.

Maintenance and Preventative Work

• Carry out routine preventative maintenance on motors and related equipment to reduce downtime and extend operational life.
• Inspect and service components like bearings, brushes, and cooling fans to ensure optimal motor performance.
• Advise maintenance teams on proper handling and operation of electrical motors to prevent premature failure.

Safety and Compliance

• Follow all company safety policies and electrical safety regulations while performing rewinding and repair tasks.
• Use personal protective equipment (PPE) and ensure the workshop environment is safe and hazard-free.
• Handle hazardous materials such as insulating varnishes, solvents, and cleaning agents responsibly.
• Participate in safety training sessions and contribute to continuous improvement of safety procedures.

Collaboration and Communication

• Work closely with engineering, maintenance, and production teams to plan rewinding schedules and prioritize urgent repairs.
• Provide technical advice and support to colleagues and clients regarding motor operation and maintenance best practices.
• Communicate clearly any delays, challenges, or resource needs to supervisors.
• Assist in training junior technicians or apprentices in motor rewinding techniques and safety practices.

KEY REQUIREMENT SKILLS AND QUALIFICATION

• Diploma or Degree in Electrical Engineering, Electrical & Electronics Engineering, or related field
• Minimum of 5 years proven experience in motor rewinding and repair
• Strong understanding of the operation and maintenance of AC/DC motors, alternators, and transformers
• Proficient in the use of testing instruments such as multimeters, megohmmeters, and other diagnostic tools
• Skilled in the use of winding machines, hand tools, and other motor repair equipment
• Excellent problem-solving skills with a keen attention to detail and high level of accuracy
• Ability to read and interpret electrical schematics and technical drawings
• Strong commitment to safety and quality standards