Deputy Manager - Maintenance - Foundry

Responsibilities & Key Deliverables

In Maintenance department at Swaraj Foundry you will play a pivotal role in overseeing and enhancing the efficiency of critical manufacturing equipment within the foundry environment. Your responsibilities will encompass the operation, maintenance, and continuous improvement of advanced machinery including Kunkel Wagner make HPML (High Pressure Moulding Line), Sand Plant, and Loramendi make core shooter machines, complemented by ABB robot systems. You will leverage comprehensive knowledge of KW HPML operation and cycle sequences, with added advantage for experience in Andromat systems.

Key deliverables include diagnosing and troubleshooting equipment malfunctions using inspection techniques on PLC logic programming specifically with Siemens S7-1500 PLC, WinCC SCADA systems, and HMI interfaces. You will be charged with maintaining Mold Shop machinery, Sand Plant, and Loramendi core shooters to achieve the highest standards of uptime, cost efficiency in spares, and energy usage reduction.

Further responsibilities involve ensuring optimal equipment utilisation to meet stringent production targets, fostering a safe and compliant working environment, and maintaining instrumentation along with PLC programming nuances integral to the manufacturing process. Expertise in SEW Movitools software for configuring and fine-tuning SEW Variable Frequency Drives (VFDs) will be employed routinely.

In addition to hands-on maintenance, you will actively contribute to digital transformation initiatives, TPM (Total Productive Maintenance), Lean Manufacturing, and Kaizen continuous improvement programs, aiming at sustainable operational excellence. Ensuring adherence to legal, industrial, and ISO quality standards forms a core part of your role, underpinning our commitment to compliance and quality assurance.

You will participate in cross-functional collaboration, driving projects to optimise maintenance procedures, reduce downtime, and support the business unit’s strategic goals. Effective communication and leadership skills will assist you in mentoring technical teams and liaising with various stakeholders to support plant operations and asset management strategies.

Preferred Industries

Education Qualification

The ideal candidate will hold a Bachelor of Technology (BTech) degree in Electrical Engineering or an equivalent qualification from a recognised institution, providing a robust understanding of electrical systems, automation, and control technologies pertinent to advanced manufacturing equipment. A strong foundational knowledge of mechanical engineering principles and manufacturing methodologies is highly desirable, given the interdisciplinary nature of maintenance operations in foundry settings.

Additional professional certifications or training relevant to CNC programming, PLC systems (notably Siemens S7 series), robotics, and maintenance management are strongly preferred, as they demonstrate a commitment to professional excellence and preparedness to handle complex technical challenges.

• Bachelor’s degree in Electrical Engineering or related engineering discipline
• Professional certifications in CNC programming, PLC operation, or maintenance engineering (preferred)
• Strong technical aptitude with capability to interpret and manage schematics, blueprints, and digital control systems
• Commitment to continuous learning and staying updated with emerging manufacturing technologies and standards

Traineeship or advanced courses in digital manufacturing tools, such as SCADA systems, automation software, and Industry 4.0 concepts, will be considered an additional advantage.

General Experience

Applicants must demonstrate a minimum of seven years of progressive professional experience within equipment maintenance roles in industrial sectors such as tractor manufacturing, foundry operations, or the automotive industry. Experience must encompass hands-on maintenance, diagnostics, and repair activities on CNC Vertical Machining Centre (VMC) machines as well as allied electrical and mechanical systems, reflecting a well-rounded technical capability.

The role requires proven leadership experience in supervising cross-functional maintenance teams responsible for executing comprehensive maintenance schedules, enforcing safety protocols, and executing process improvements.

Additionally, candidates with experience in maintenance resource management, including budgeting, procurement of spares, and vendor liaison, will find their skills highly relevant for this role. Proficiency in maintaining meticulous maintenance documentation and utilizing statistical data analysis to monitor machine performance, identify trends, and implement preventive measures is essential.

• Minimum 7 years in industrial equipment maintenance with specific experience in heavy machinery and automation systems
• Hands-on proficiency with CNC programming, fault diagnosis, and PLC troubleshooting
• Demonstrated ability to lead and develop multidisciplinary maintenance teams
• Experience with maintenance planning, budgeting, and procurement functions
• Ability to analyze maintenance and operational data to optimise equipment reliability and availability

This role offers the opportunity to build upon existing knowledge by engaging in innovative maintenance strategies and continuous improvement programs in a dynamic manufacturing environment.

Critical Experience

This role demands critical expertise in CNC programming, particularly tailoring VMC machine operations for precision and efficiency within a manufacturing foundry context. You will apply advanced CNC programming techniques to optimise machine performance and product quality.

Experience with Product Lifecycle Management (PLM) systems is integral, supporting the oversight of machinery from commissioning to end-of-life, thereby maximising operational uptime and return on investment. Utilizing PLM platforms ensures rigorous control over maintenance schedules, spare parts tracking, and asset management.

Proficiency in statistical analysis tools and methodologies is essential to interpret maintenance and operational data reliably. You will leverage these insights to predict equipment failures, schedule proactive interventions, and reduce both unexpected downtime and maintenance costs.

Knowledge of specialised jigs and fixtures tailored to casting and machining processes is required to maintain manufacturing precision and efficiency. You will apply this understanding to support quality objectives and ensure smooth production workflows.

• Expertise in CNC programming with a focus on VMC machining within a foundry setting
• Advanced application of Product Lifecycle Management solutions for equipment and maintenance management
• Strong statistical analysis capabilities to underpin data-driven maintenance decisions
• In-depth understanding of jigs and fixtures specific to casting and machining operations
• Track record integrating these competencies effectively within maintenance supervision and execution roles

Your capability to synthesise these critical experiences will directly contribute to the department's operational excellence and equipment reliability.

System Generated Core Skills

System Generated Secondary Skills