Foundry Maintenance Manager

Manager Maintenance - Foundry

Responsibilities & Key Deliverables

• The Manager Maintenance - Foundry will play a pivotal role in ensuring the seamless operation and reliability of high-pressure moulding lines, sand plants, and core shooter machines, particularly those manufactured by Kunkel Wagner and Loramendi. Expertise in ABB robot operation and maintenance is essential, with practical experience in Andromat systems considered advantageous. This role demands a proactive approach to planning, overseeing, and executing preventive, predictive, and corrective maintenance activities of all electrical and mechanical systems associated with foundry operations.
• Core responsibilities include leading root-cause analysis initiatives to address equipment failures promptly and implementing sustainable corrective measures. Candidates will be expected to demonstrate proficiency in diagnosing and troubleshooting using Siemens S7-1500 PLC logic, WinCC SCADA systems, HMI interfaces, as well as configuring SEW Movitools software for variable frequency drive (VFD) setup and parameter adjustments.
• Ensuring optimal utilization of foundry equipment, including HPML, sand plants, Loramendi core shooters, and associated instrumentation, forms a fundamental part of the day-to-day duties. Maintaining equipment uptime with minimal costs on spares and energy consumption will be supported by innovative practices such as condition-based maintenance for critical mechanical systems, including gearboxes, hydraulic and pneumatic mechanisms, and bearings.
• Additionally, this role encompasses oversight of high-voltage equipment critical to melt shop operations – such as EHV/HV/LT switchgear, 11kV and 33kV transformers, induction melting furnaces and their cooling systems – ensuring compliance with safety and operational standards.
• Experience in continuous improvement methodologies such as TPM, Lean Manufacturing, Kaizen, and digital transformation initiatives is expected to enhance operational efficiency. The_MANAGER will monitor power usage to drive energy optimisation across the foundry and actively uphold legal and safety standards complying with IE/IS/ISO regulations and Indian Electricity Rules, including documentation for audits and certifications.
• Mechanical maintenance oversight extends to melting furnaces, moulding lines, shakeout and cooling lines, sand preparation and reclamation systems, core making machines, cranes, hoists, and material handling equipment. The role also involves strategic spares planning to ensure the availability of critical components and support for the installation, commissioning, and stabilization of new machinery and utilities.

Preferred Industries

Auto / Auto EquipmentAutomobileAuto ComponentsAutomotive IndustryAuto ancilliaryFoundry

Education Qualification

The ideal candidate will possess a robust educational background in engineering, with qualifications including but not limited to:

• Bachelor of Engineering (B.E.) or Bachelor of Technology (B.Tech) i

General Experience

Applicants must demonstrate a minimum 15 years of comprehensive experience within foundry environments, with specific emphasis on maintenance management. Proven success in managing large-scale electrical and mechanical systems, preventive maintenance scheduling, and coordination of multi-disciplinary teams is essential.

Strong communication, leadership, and organisational skills obtained through prior roles should demonstrate the ability to drive continuous improvement and foster a safety-centric culture.

Critical Experience

Critical to success in this role is hands-on experience with Kunkel Wagner HPML systems, Loramendi core shooter machinery, and sand plants, augmented by competencies in ABB robotic system operation and maintenance. Experience as Electrical Preventive Maintenance Incharge within high-pressure moulding lines is highly desirable.

The candidate must possess advanced skills in Siemens S7-1500 PLC programming, WinCC SCADA management, HMI troubleshooting, and SEW Movitools software for VFD parameterization. Proficient understanding and management of high-voltage equipment such as EHV/HV/LT switchgear, transformers, and induction melting furnaces are mandatory.

Demonstrated capability in implementing digitization initiatives, Lean Manufacturing principles, TPM frameworks, and Kaizen continuous improvement processes is essential to optimise maintenance efficiency and reliability.

Knowledge and application of legal compliance aligned with Indian Electricity Rules, CEA safety regulations, and other statutory mandates is mandatory to ensure workplace safety and regulatory adherence. Experience handling audit processes, including CEI and internal Mahindra audits, with a focus on documentation and safety certifications is an important credential.

Mechanical maintenance proficiency covering melting furnaces, moulding and cooling lines, sand preparation systems, and material handling equipment is essential. Experience in spares management, condition-based maintenance implementation, and new equipment commissioning rounds out the critical experience required to lead this role effectively.

System Generated Core Skills

Communication SkillsReview MechanismMaintenance ManagementSupplier DevelopmentEquipment EvaluationBudgeting & CostingRetrofittingAuditingOccupational Health & Safety (OHS)Organizational Behavior ManagementLiasoningWater ManagementNoise ControlPollution PreventionDigitization

System Generated Secondary Skills

Experience Level

Mid Level