Assistant General Manager - Maintenance

Job Title: Assistant General Manager – Maintenance

Job Purpose

To lead and manage electrical and mechanical maintenance of foundry operations ensuring continuous plant availability, safe operations, statutory compliance, energy efficiency, and cost optimization, supporting high-quality casting production.

Roles & Responsibilities

1. Foundry Equipment Maintenance

• Maintenance of induction furnaces, ladles, power packs, cooling systems, and furnace auxiliaries.
• Maintenance of Molding lines, sand mixers, reclamation plants, Knock out machines, Heat Treatment furnaces, Welding Machines, shot blasting machines, conveyors, cranes, and finishing equipment.
• Ensure high reliability of core shop and fettling shop machinery.
• Support shutdown planning and major overhauls.

2. Electrical Maintenance (Foundry Specific)

• Operation and maintenance of HT/LT systems, transformers, substations, capacitor banks, DG sets, UPS, MCCs, PLCs, VFDs, SCR panels, and induction furnace power panels.
• Ensure compliance with CEIG, Electrical Inspectorate, and electrical safety norms.
• Manage power quality, harmonic control, and furnace load balancing.
• Monitor and optimize specific power consumption (kWh/MT of casting).

3. Mechanical Maintenance

• Preventive and breakdown maintenance of gearboxes, hydraulic systems, pneumatic systems, compressors, pumps, cooling towers, and pipelines.
• Maintenance of EOT cranes, hoists, ladle handling systems, and lifting equipment.
• Root cause analysis of mechanical failures and corrective actions.

4. Utilities & Infrastructure

• Manage compressed air systems, cooling water circuits, chillers, sand plant utilities, and dust extraction systems.
• Maintenance of foundry buildings, structures, electrical cabling, earthing systems, and lighting.
• Ensure proper operation of pollution control equipment (bag filters, scrubbers).

5. Preventive, Predictive & Reliability Maintenance

• Implement preventive and predictive maintenance schedules using CMMS.
• Track MTBF, MTTR, furnace availability, and breakdown trends.
• Introduce condition monitoring (thermography, vibration analysis, oil analysis).

6. Safety, Statutory & Compliance

• Ensure LOTO, hot work permits, confined space procedures, and PPE compliance.
• Ensure compliance with Factories Act, Electrical Rules, Fire & Safety norms, and Pollution Control Board requirements.
• Prepare and support ISO / IATF / Customer audits.
• Drive zero-accident maintenance culture.

7. Team & Contractor Management

• Lead maintenance engineers, supervisors, electricians, fitters, and technicians.
• Manage contractors for furnace maintenance, electrical shutdowns, and civil works.
• Conduct training on foundry safety, furnace operations, and emergency handling.

8. Spares, Budget & Cost Control

• Plan and control critical spares for furnaces, electrical panels, and heavy equipment.
• Manage maintenance OPEX and CAPEX budgets.
• Vendor development and AMC management for furnace suppliers and OEMs.

9. Projects & Continuous Improvement

• Lead new furnace installation, capacity expansion, and modernization projects.
• Implement TPM, 5S, Kaizen, energy-saving, and cost-reduction initiatives.
• Support automation and digital maintenance initiatives.

10. Coordination & Reporting

• Coordinate with Production, Quality, Safety, Purchase, and Stores departments.
• Prepare daily, weekly, and monthly maintenance MIS.
• Handle emergency breakdowns and power failures efficiently.

Qualification & Experience

• Diploma / BE / B.Tech – Electrical / Mechanical / EEE
• 12–20 years’ experience in foundry or heavy manufacturing
• Strong exposure to induction furnaces and foundry utilities

Skills & Competencies

• Foundry process and equipment knowledge
• Electrical and mechanical troubleshooting
• Leadership and decision-making
• Statutory compliance expertise
• Cost control and budgeting
• CMMS / ERP proficiency

Contact: 9047054309

Job Types: Full-time, Permanent

Pay: ₹80,000.00 - ₹100,000.00 per month

Benefits:

• Cell phone reimbursement
• Food provided
• Health insurance
• Provident Fund

Work Location: In person