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Maintenance Head - WNSMH05062026
Company Overview
The Company is one of India’s leading manufacturers of engineering cast components, supplying high-quality metal parts for Railway Engineering, Automobile Engineering, General Engineering, and Agriculture applications. With strong foundry and quality systems, the Company delivers reliable castings that meet Indian and international quality standards and is trusted for consistent quality, safe products, and timely delivery across industries.
Job Overview
The Maintenance Head is a Senior Leadership Role responsible for ensuring the highest levels of availability, reliability, and safety of all plant machinery, equipment, and infrastructure in a high-volume engineering castings manufacturing facility. This position plays a critical role in minimizing downtime, optimizing maintenance costs, and supporting continuous production of high-quality metal cast components for Railway, Automobile, General Engineering, and Agriculture sectors. The Maintenance Head leads a team of engineers, technicians, and supervisors while driving preventive, predictive, and breakdown maintenance strategies in a foundry environment with heavy machinery such as induction furnaces, sand preparation plants, molding lines, shot blasting machines, CNC machines, heat treatment furnaces, cranes, and material handling systems.
Key Responsibilities
- Develop, lead, and continuously improve a comprehensive maintenance strategy to transition from reactive to proactive culture ensuring maximum equipment availability and reliability.
- Align maintenance objectives with production targets, quality standards (Indian & International), and overall business goals.
- Drive implementation of Total Productive Maintenance (TPM), Preventive Maintenance (PM), Predictive Maintenance (PdM), Condition-Based Monitoring (CBM), and Reliability-Centered Maintenance (RCM) across the plant.
- Prepare, manage, and control the annual maintenance OPEX & CAPEX budgets while achieving cost-saving targets without compromising safety or quality.
- Ensure highest uptime and OEE of critical equipment including Induction Furnaces, Sand Preparation Plants, Molding Lines (Green Sand & No-Bake), Core Making Machines, Shot Blasting Machines, Heat Treatment Furnaces, CNC Machines, Cranes, and Material Handling Systems.
- Plan, schedule, and execute preventive, predictive, and corrective maintenance activities with minimum disruption to production.
- Lead rapid breakdown response, perform Root Cause Analysis (RCA), implement corrective & preventive actions, and eliminate recurring failures.
- Oversee major plant shutdowns, equipment overhauling, relocations, modernization, and new project installations including commissioning & validation.
- Implement and effectively utilize CMMS / SAP-PM for work orders, equipment history, performance tracking, and maintenance data analysis.
- Monitor and improve key maintenance KPIs such as MTBF, MTTR, OEE, Equipment Availability, Downtime Percentage, and Maintenance Cost per Tonne.
- Manage spare parts inventory using ABC/VED analysis, develop critical spares list, and maintain optimum inventory levels.
- Coordinate with OEMs, vendors, and service providers for specialized repairs, technical support, Annual Maintenance Contracts (AMCs), and equipment upgradation.
- Ensure strict compliance with all safety standards, environmental norms, and statutory requirements (Factory Act, PESO, Pollution Control Board, etc.).
- Champion safety in maintenance by enforcing LOTO, Permit-to-Work systems, Job Safety Analysis (JSA), and promote zero Lost Time Injuries (LTI) culture.
- Maintain dust extraction systems, Effluent Treatment Plants (ETP), and other utilities to meet environmental and workplace safety standards.
- Support and ensure compliance with Quality Management Systems (ISO 9001, IATF 16949) and sector-specific requirements related to equipment reliability.
- Identify and execute opportunities for equipment automation, technology upgradation, energy conservation, and process improvements.
- Provide strong leadership, mentoring, and development to a multi-disciplinary team of maintenance engineers, supervisors, technicians, and contractors.
- Build high-performance teams, establish clear roles & accountability, and conduct regular performance reviews and skill development programs.
- Drive digital transformation and adoption of CMMS/SAP-PM modules for better maintenance planning and decision making.
- Manage utility systems including air compressors, power sub-stations, DG sets, cooling systems, and EOT cranes to ensure uninterrupted support to production.
- Focus on asset reliability of foundry-specific equipment such as furnace lining management, sand plant precision, and post-processing machinery (CNC, Heat Treatment, Shot Blasting).
- Develop and maintain Standard Operating Procedures (SOPs), checklists, and best practices for all maintenance activities.
- Analyze maintenance data & trends to drive continuous improvement initiatives using Lean, Six Sigma, and TPM tools.
- Prepare periodic reports on maintenance performance, downtime analysis, cost trends, and improvement actions for the Plant Head / Senior Management.
Key Skills
- Strong technical expertise in maintenance of foundry-specific equipment including Induction Furnaces, Sand Preparation Plants, Molding Lines, Core Shooters, Shot Blasting Machines, Heat Treatment Furnaces, CNC Machines, and Material Handling Systems.
- In-depth knowledge of Preventive Maintenance (PM), Predictive Maintenance (PdM), Condition-Based Monitoring (CBM), Total Productive Maintenance (TPM), and Reliability-Centered Maintenance (RCM).
- Proficiency in using predictive maintenance tools such as Vibration Analysis, Infrared Thermography, and Oil Analysis.
- Mastery in Root Cause Analysis techniques including 5-Why, 8D, Fishbone Diagram, and FMEA for eliminating recurring failures.
- Hands-on experience with CMMS, SAP-PM, and ERP systems for effective maintenance planning and data analysis.
- Excellent leadership and team management skills with the ability to mentor, develop, and upskill multi-disciplinary maintenance teams.
- Strong expertise in electrical, mechanical, hydraulic, pneumatic systems, PLC, SCADA, and CNC troubleshooting.
- Sound knowledge of safety standards including LOTO, Permit-to-Work, JSA, and foundry-specific SHE requirements.
- Proficiency in budgeting, cost control, CAPEX planning, and spare parts inventory management using ABC/VED analysis.
- Deep understanding of key maintenance KPIs such as OEE, MTBF, MTTR, Equipment Availability, and Maintenance Cost per Tonne.
- Skilled in vendor management, negotiation, and handling Annual Maintenance Contracts (AMCs) with OEMs and contractors.
- Thorough knowledge of Indian and International quality standards (ISO 9001, IATF 16949) and their application in maintenance.
- Ability to read and interpret technical drawings, equipment manuals, P&IDs, and PLC programs.
- Strong project management skills for planning and executing major shutdowns, equipment overhauling, and modernization projects.
- Expertise in energy conservation, utility management, and implementation of automation technologies in foundry operations.
- Excellent analytical, problem-solving, communication, and cross-functional collaboration skills with a focus on change management.
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₹70000/- to ₹90000/- pm (Best in the Industry for Qualified Candidate)
Industry
Foundry and Metal Casting Manufacturing Industry
Age Limit
Maximum 45 Years
Gender Preference
Male Only
Male Only
Education
Any Diploma / B.E. / B.Tech / Relevant in Mechanical Engineering / Electrical Engineering / Industrial Engineering from a recognized university. Strong foundry or heavy engineering maintenance background is on priority.
Experience
Minimum 5 to 7 years of experience as a Maintenance Head in Engineering Castings / Foundry / Heavy Manufacturing Industries, Experience in leadership role handling Plant Maintenance, Team Management, and High-Volume Production Environments. Strong foundry or heavy engineering maintenance background experience is on priority.
Location
Ahmedabad - Gujarat | India
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