Electrical & Mechanical Maintenance- Foundry

Symbiosis Management Consultants; Chandigarh, Delhi; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

Symbiosis Management Consultants seeks an experienced Electrical & Mechanical Maintenance lead for our foundry operations. You will oversee HPML, Sand Plant, Core Shop and utilities, driving preventive, predictive and breakdown maintenance to boost equipment availability.

Lead root cause analysis using structured methods and implement sustainable actions. Manage ABB robots, PLC/SCADA systems, and energy-efficient improvements while maintaining compliance with safety and ISO standards.

Qualifications

• Candidate should have extensive experience in electrical and mechanical maintenance of foundry operations.
• Experience with HPML, Sand Plant, Core Shop, Mold Shop, and utilities is required.
• Strong background in preventive, predictive and breakdown maintenance, with data-driven improvement.
• Knowledge of IATF/TS, safety standards and regulatory compliance is essential.

Responsibilities

• Lead end-to-end maintenance of Foundry operations including HPML, Sand Plant, Core Shop, Mold Shop and utilities.
• Plan, execute and monitor preventive, predictive, CBM, and breakdown maintenance to maximize equipment availability.
• Drive improvements in MTBF and MTTR and minimize downtime.
• Conduct RCA using Why-Why, 5W1H and Ishikawa diagrams and implement corrective actions.
• Manage ABB Robots, automation systems, and SEW VFDs; optimize PLC/SCADA networks.
• Update SAP-PM records and maintain maintenance KPIs.

Skills

Electrical maintenance

Mechanical maintenance

Preventive maintenance

Root cause analysis

TPM / Lean manufacturing

DWM / maintenance metrics

Education

B.E./B.Tech in Electrical or Mechanical

Tools

Siemens S7-1500 PLC

WinCC SCADA

HMI systems

SEW VFDs Movitools

SAP-PM

ABB Robots

Job description

Role- Electrical & Mechanical Maintenance-Foundry

Experience- 15+ Years

Roles & Responsibilities

Foundry Maintenance (Mechanical & Electrical)

• Lead end-to-end maintenance of Foundry operations including HPML (High Pressure Moulding Line), Sand Plant, Core Shop, Mold Shop, Utilities, and associated equipment.
• Plan, execute, and monitor preventive, predictive, condition-based (CBM), and breakdown maintenance activities to ensure maximum equipment availability.
• Drive improvements in MTBF (Mean Time Between Failures), reduce MTTR (Mean Time To Repair), and minimize breakdown frequency and downtime.
• Conduct Root Cause Analysis (RCA) using Why-Why Analysis, 5W1H, Fishbone (Ishikawa) Diagram, and implement sustainable corrective actions.
• Maintain and improve reliability of Kunkel Wagner HPML, Loramendi Core Shooter Machines, Sand Plant systems, and related foundry equipment.
• Manage operation and maintenance of ABB Robots, automation systems, and material handling equipment.
• Troubleshoot and optimize Siemens S7-1500 PLC, WinCC SCADA, HMI systems, sensors, and industrial control networks.
• Configure, diagnose, and optimize SEW VFDs using Movitools software to improve machine performance and energy efficiency.
• Ensure uninterrupted plant utility operations and electrical power management across the foundry.
• Monitor energy consumption, analyze energy data, and implement energy-saving and power cost reduction projects.
• Carry out load assessment, electrical load mapping, and power distribution planning for capacity expansion and new installations.
• Lead installation, commissioning, testing, and stabilization of new machines, production lines, and utility systems.
• Develop and execute annual maintenance plans, shutdown activities, and equipment lifecycle improvement initiatives.
• Ensure 100% adherence to preventive maintenance schedules and condition monitoring parameters.
• Manage maintenance budgets, spare parts inventory, vendor development, and cost optimization initiatives.
• Drive TPM, Lean Manufacturing, Kaizen, Digitization, and Continuous Improvement projects to enhance operational efficiency.
• Update and maintain SAP-PM records, maintenance history, equipment master data, and maintenance KPIs.
• Ensure compliance with IATF/TS documentation requirements, audit readiness, and maintenance procedures.
• Ensure compliance with statutory requirements, CEA regulations, Indian Electricity Rules, IE/IS standards, ISO requirements, and safety guidelines.
• Handle liaisoning and approvals related to electrical installations, CEI inspections, statutory audits, and regulatory compliances.
• Ensure adherence to EHS standards and foster a zero-harm safety culture across maintenance operations.
• Lead, develop, and supervise maintenance teams, contractors, and service providers for effective manpower utilization.
• Drive Daily Work Management (DWM) practices and monitor plant performance through key maintenance and reliability metrics.
• Ensure optimum machine utilization, minimum downtime, reduced spare consumption, and sustained operational excellence across the foundry.