Maintenance Manager (Forge)

AP Management Consultants; Bengaluru; On-site; INR 781,000 - 893,000; Full time

Benefits offered by this job

Salary 70-80k

Job summary

AP Management Consultants in Bengaluru (Karnataka) seeks an experienced Maintenance Leader for hot forging operations. You will oversee maintenance standards, lead shifts, and drive TPM programs to prevent breakdowns across presses, heaters, and cooling utilities.

The role requires 10+ years in heavy press plants, hands-on expertise, and strong RCA/CAPA discipline, with ERP/Microsoft Office proficiency and strict safety adherence.

Qualifications

• B.E./B.Tech./Diploma in Mechanical Engineering.
• 10+ years of maintenance leadership in hot forge/heavy press plants.
• Hands-on expertise in heavy forging presses, hydraulic power packs, valves, pneumatics, and billet heaters.
• Proven RCA, TPM, MTTR/MTBF tracking and CAPA implementation.
• ERP maintenance tracking systems and MS Office proficiency.

Responsibilities

• Develop and enforce maintenance standards to ensure reliability of hot forging equipment.
• Design and execute preventive, predictive TPM schedules and monitor MTTR/MTBF.
• Lead shift maintenance teams, allocate workloads, and coordinate breakdown response.
• Diagnose mechanical/pneumatic/hydraulic failures; perform RCA and implement CAPA.
• Manage spare parts inventory and liaise with suppliers to avoid production stoppages.
• Enforce safety, EHS, LOTO, audits, and maintain ISO/IATF compliance records.
• Drive continuous improvement and cost-reduction projects to boost productivity.

Skills

Maintenance Leadership

TPM & MTTR/MTBF

Root Cause Analysis

MS Office & ERP

Education

B.E./B.Tech./Diploma in Mechanical Engineering

Tools

MS Excel

MS Word

ERP maintenance systems

Job description

Industry / Plant: Hot Forging Manufacturing

Role & responsibilities

Key Responsibilities & Operational Scope

• Equipment Maintenance & Uptime: Develop and execute rigorous maintenance standards to ensure optimal reliability of hot forging presses (screw/crank/friction), induction billet heaters, trimming presses, and cooling tower utilities.
• Preventive & Predictive Maintenance (TPM): Design, implement, and track daily, weekly, and monthly preventive schedules to eliminate recurring machine breakdowns while maintaining MTTR/MTBF metrics.
• Team Leadership & Shift Planning: Lead, coach, and allocate workloads for shift maintenance engineers, technicians, and ITI fitters to ensure rapid breakdown response across all production shifts.
• Breakdown Troubleshooting & RCA: Diagnose complex mechanical, pneumatic, and high-pressure hydraulic circuit failures promptly; conduct in-depth Root Cause Analysis (RCA) and implement CAPA to prevent recurrence.
• Spare Parts & Inventory Control: Manage critical spares inventory (hydraulic pumps, valves, seal kits, bearings, induction coils), liaise with suppliers, and ensure timely procurement to avoid production halts.
• Safety, EHS & Statutory Compliance: Enforce strict plant safety standards (Lockout/Tagout - LOTO, PPE adherence, work permits), conduct routine safety audits, and maintain audit-ready maintenance logs for ISO / IATF standards.
• Continuous Improvement & Cost Control: Identify equipment bottlenecks, initiate kaizen/cost-reduction projects, optimize power/utility consumption, and improve overall forging press productivity.

Required candidate profile

• Education: B.E. / B.Tech / Diploma in Mechanical Engineering.

Experience:

• 10+ years of proven maintenance leadership experience in a Hot Press Forging or heavy press engineering plant.
• Technical Expertise: Hands-on expertise in heavy forging presses, hydraulic power packs, proportional valves, pneumatics, and billet heaters.
• Problem Solving: Proven proficiency in breakdown Root Cause Analysis (RCA), 5-Why Analysis, TPM methodology, and MTTR/MTBF tracking.
• Software & Reporting: Working proficiency in MS Office (Excel & Word) and ERP maintenance tracking systems.
• Leadership: Strong team management skills, proactive shift allocation, and quick decision-making during critical breakdowns.

Perks and benefits

70,000 80,000 per month

Work Schedule:

8 Hours Duty | General / Rotational Breakdown Support

Industry / Plant:

Hot Forging Manufacturing