Maintenance Manager

Job Description – Maintenance Manager (Foundry Plant)

Company: Patil Rail Infrastructure Pvt Ltd
Location: Kallakal, Telangana
Department: Maintenance
Industry: Railway Manufacturing / Foundry (Steel / Castings / Precast Components)
Experience: 12–20 Years
Reporting To: Plant Head

Role Purpose

To lead and manage the complete maintenance function of the foundry plant, ensuring maximum equipment uptime, reliability, safety compliance, and cost efficiency across all mechanical, electrical, and utility systems.

Key Responsibilities

1. Maintenance Operations

   • Lead end-to-end maintenance of foundry equipment including:
     • Induction furnaces / melting units
     • Sand plant systems
     • Shot blasting machines
     • Material handling systems (EOT cranes, conveyors)
     • Compressors, hydraulics & utilities
   • Plan and execute preventive, predictive, and breakdown maintenance programs to improve equipment reliability.
   • Ensure minimum downtime and quick restoration during breakdowns.

2. Plant Reliability & Uptime

   • Drive initiatives to improve equipment uptime and reduce maintenance cost.
   • Analyze failure trends, root cause analysis (RCA), and implement corrective actions.
   • Maintain MTBF, MTTR, and other maintenance KPIs.

3. Team Management

   • Lead a team of engineers, supervisors, and technicians.
   • Allocate work, monitor performance, and ensure skill development.
   • Establish maintenance SOPs and best practices.

4. Shutdown & Project Management

   • Plan and execute annual shutdowns and major overhauls.
   • Coordinate with production for maintenance schedules.
   • Support plant expansion, equipment installation, and commissioning.

5. Safety & Compliance

   • Ensure adherence to:
     • Industrial safety norms
     • Statutory compliance (Factories Act, Pollution norms)
   • Implement safety audits, LOTO procedures, and risk assessments.
   • Ensure zero accident culture within maintenance team.

6. Budgeting & Cost Control

   • Prepare and manage maintenance budgets.
   • Monitor spares consumption, inventory, and cost optimization.
   • Approve purchase requisitions and vendor selection.

7. Vendor & Spare Management

   • Develop vendor base for critical equipment and spares.
   • Ensure availability of critical spares for uninterrupted operations.
   • Negotiate AMC/Service contracts.

8. Continuous Improvement

   • Implement TPM / Lean / Kaizen initiatives.
   • Introduce predictive maintenance tools (vibration analysis, thermography).
   • Drive automation and digital maintenance systems (SAP/CMMS).

Key Skills Required

• Strong knowledge of foundry equipment & heavy engineering maintenance
• Expertise in mechanical + electrical maintenance
• Knowledge of hydraulics, pneumatics, and utilities
• Strong leadership and team handling skills
• Exposure to SAP / CMMS systems
• Problem-solving and analytical mindset

Educational Qualification

• B.E / B.Tech – Mechanical / Electrical / Production Engineering
• Additional certifications in TPM / Reliability / Maintenance preferred

Experience

• 12–20 years in foundry / steel / heavy manufacturing / railway components industry
• Minimum 5+ years in leadership role (Maintenance Head / Manager level)
• Experience in induction furnace / casting / sleeper / precast plants preferred

KPIs / Performance Metrics

• Equipment uptime (%)
• Breakdown frequency reduction
• Maintenance cost per ton
• Safety compliance & zero accidents
• Spare inventory optimization
• Shutdown adherence timelines