Manager, Maintenance & Facilities

Armstrong Fluid Technology; Bengaluru; On-site; INR 4,000,000 - 6,200,000; Full time

Job summary

Armstrong Fluid Technology in Bengaluru seeks a senior maintenance leader to own reliability, energy efficiency, and cost-effective upkeep across critical plant assets. You will drive Lean/ TPM, automation initiatives, and digitalization to elevate productivity and safety.

The role requires steering a multi-disciplinary team, optimizing spares, planning shutdowns, and delivering measurable improvements in OEE and asset lifecycle management.

Qualifications

• Education: E./B. Tech in Mechanical or Electrical Engineering.
• Experience: 15–20 years in maintenance with 5+ years in leadership.
• Preferred: TPM, Lean Six Sigma Green/Black Belt, CMRP or reliability certifications.
• Hands-on knowledge of electrical systems, machine tools, furnaces, hydraulics, and pneumatics.
• Experience with PLC, SCADA, VFDs, CMMS and condition monitoring tools.
• Strong budgeting, project management, vendor negotiation and data-driven decisions.

Responsibilities

• Lead rapid response to breakdowns with defined escalation and restoration targets.
• Conduct root-cause analysis (5-Why, Fishbone, Why-Why, FMEA) and close CAPAs.
• Build preventive maintenance schedules, lubrication plans, and calibration schedules.
• Implement predictive maintenance using vibration analysis, thermography, oil analysis, and more.
• Maintain asset register, criticality ranking, and lifecycle history.
• Plan shutdowns and overhauls with minimal production impact.
• Manage critical spares, min-max levels, and indigenization of spares.
• Lead TPM program across pillars and drive OEE improvements and cost control.
• Drive automation and Industry 4.0 roadmap; integrate CMMS/ERP effectively.
• Oversee safety, budget control, and compliance with statutory requirements.

Skills

Leadership

Cross-functional collaboration

Problem solving

Education

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

Tools

PLC

SCADA

VFDs

CMMS

SAP PM

Condition monitoring tools

Job description

Imagine working at the forefront of innovation in fluid-flow technology, with over 1,400 colleagues across the globe, and contributing to a legacy of excellence that spans eight manufacturing facilities on four continents. Armstrong Fluid Technology is more than just a leader in our industry; we are a community of the brightest and most creative minds, driven by a shared mission to engineer the future and safeguard our planet.

As part of our team, you'll be immersed in an environment that fosters growth, creativity, and collaboration. Here, you'll have the opportunity to push boundaries, tackle exciting challenges, and develop cutting-edge solutions that promote energy efficiency and reduce environmental impact. Every day offers the chance to make a meaningful contribution to a more sustainable future, driving innovations that help lower global carbon footprints. Together, we’re creating a legacy that goes beyond business—one that’s changing the world for the better.

In this role, the incumbent will be accountable for the availability, reliability, safety, and cost-effective upkeep of all electrical and mechanical assets across the pump Assembly facility and the non-ferrous foundry. The role goes beyond breakdown response. It is expected to drive manufacturing excellence by deploying Lean and TPM, leading automation and digitalization, and improving productivity, energy efficiency, and profitability.In this role, as an Associate Manager

Key Accountabilities

• Lead rapid response to electrical and mechanical breakdowns, with defined escalation, response time, and restoration targets.
• Conduct structured root cause analysis (5-Why, Fishbone, Why-Why, FMEA) for every major or repeat failure, and close corrective and preventive actions (CAPA).
• Build and execute preventive maintenance (PM) schedules, lubrication plans, and calibration schedules for all critical equipment.
• Implement predictive maintenance using vibration analysis, thermography, oil analysis, motor current signature analysis, and ultrasonic testing.
• Maintain the asset register, equipment criticality ranking (A/B/C), and lifecycle history.
• Plan and execute shutdown and overhaul activities (furnace relining, major machine overhauls, panel maintenance) with minimal production impact.
• Manage critical spares: set min-max levels, reduce obsolete stock, and develop alternate vendors and indigenization of spares.

Breakdown Management and Equipment Upkeep

• Lead rapid response to electrical and mechanical breakdowns, with defined escalation, response time, and restoration targets.
• Conduct structured root cause analysis (5-Why, Fishbone, Why-Why, FMEA) for every major or repeat failure, and close corrective and preventive actions (CAPA).
• Build and execute preventive maintenance (PM) schedules, lubrication plans, and calibration schedules for all critical equipment.
• Implement predictive maintenance using vibration analysis, thermography, oil analysis, motor current signature analysis, and ultrasonic testing.
• Maintain the asset register, equipment criticality ranking (A/B/C), and lifecycle history.
• Plan and execute shutdown and overhaul activities (furnace relining, major machine overhauls, panel maintenance) with minimal production impact.
• Manage critical spares: set min-max levels, reduce obsolete stock, and develop alternate vendors and indigenization of spares.

Electrical Systems Responsibility

• Ensure reliable, safe operation of HT/LT distribution, transformers, motors, drives (VFDs), soft starters, and control panels.
• Maintain power quality (power factor, harmonics) and manage load, demand, and tariff optimization.
• Oversee induction furnace power supplies, cooling circuits, and safety interlocks.
• Ensure earthing, lightning protection, and electrical safety audits are current, along with compliance with electrical statutory requirements.
• Manage DG, UPS, and backup power readiness.

Mechanical Systems Responsibility

• Ensure health of machine tools (spindles, ball screws, guideways, hydraulics, coolant systems) and foundry equipment (furnaces, die casting machines, sand plant, conveyors).
• Manage compressed air, cooling water, hydraulic, and pneumatic systems for efficiency and leak reduction.
• Oversee die and tooling maintenance to reduce casting rejections caused by tool condition.
• Drive machine accuracy and capability recovery in line with quality requirements (machine capability studies, geometric alignment checks).

Lean and TPM Implementation

• Lead a plant-wide TPM program covering the pillars: Autonomous Maintenance (Jishu Hozen), Planned Maintenance, Focused Improvement (Kaizen), Early Equipment Management, Quality Maintenance, Training and Education, Safety, Health and Environment, and Office TPM.
• Roll out 5S, visual management, standardized work, and one-point lessons.
• Train and empower operators to perform cleaning, inspection, and lubrication (CIL) with defined standards.
• Reduce the six big losses and improve OEE through SMED, quick changeovers, and minor stoppage elimination.
• Run Kaizen events, a Suggestion Scheme, and Quality Circles; pursue TPM award certification (e.g., JIPM or CII-TPM) as a stretch goal.
• Integrate maintenance with value stream mapping and production planning to support flow and takt time.

Automation and Digital Transformation

• Develop and execute a multi-year automation and Industry 4.0 roadmap.
• Drive automation in the pump plant (robotic loading and unloading, automated test benches, in-line gauging, AGVs, vision inspection) and the foundry (automated ladling and pouring, die
• spray and extraction, melt monitoring, sand control, and furnace temperature and energy control).
• Implement and upgrade PLC, SCADA, HMI, and IoT-based machine monitoring for real-time OEE, downtime capture, and energy tracking.
• Deploy and optimize CMMS/EAM (e.g., SAP PM or equivalent) with work order discipline, mobile access, and analytics.
• Introduce condition monitoring sensors and dashboards, and explore AI-based predictive maintenance.
• Build business cases (ROI, payback) for automation projects and manage them from concept to commissioning in coordination with Projects.
• Reduce dependency on manual operations and improve safety, consistency, and throughput.

Business Enhancement and Cost Excellence

• Prepare, own, and control the maintenance budget (OPEX and CAPEX); reduce maintenance cost per unit produced without compromising reliability.
• Lead energy conservation initiatives: furnace efficiency, compressed air optimization, VFD retrofits, heat recovery, and renewable integration.
• Improve capacity utilization and throughput by debottlenecking critical equipment.
• Support new product introduction, capacity expansion, and new plant or line commissioning with maintainability input (design review, spares planning).
• Evaluate repair vs. replace vs. retrofit decisions with total cost of ownership analysis.
• Negotiate AMCs, service contracts, and vendor performance agreements; develop local vendors and in-house repair capability.
• Link maintenance KPIs to business outcomes such as on-time delivery, rejection reduction, and cost per casting or pump.

Safety, Health, Environment, and Compliance

• Enforce a safe maintenance culture: permit-to-work, lockout-tagout (LOTO), confined space, hot work, work at height, and safe handling of molten metal.
• Ensure statutory compliance for factory, electrical, boiler and pressure vessel, lifting equipment, fire safety, and pollution control requirements.
• Maintain emission control and effluent systems (fume extraction, scrubbers, ETP) in working condition.
• Conduct regular risk assessments and safety audits; target zero lost-time incidents in maintenance.
• Support ISO 9001, ISO 14001, ISO 45001, and IATF/customer audit requirements as applicable.

People Leadership and Capability Building

• Lead, mentor, and develop a multi-skilled team of engineers, supervisors, and technicians.
• Design skill matrices and multi-skilling programs (mechanical, electrical, PLC, hydraulics).
• Plan shift coverage, contractor manpower, and succession for critical roles.
• Build a culture of ownership, discipline, and continuous improvement.
• Conduct performance reviews and set clear KPIs for each team member.

List of Assets/Operations

Pump Assembly

• CNC and VMC machining centres, lathes, boring, grinding, and drilling machines
• Assembly lines, hydraulic and pneumatic fixtures, and test benches (performance, NPSH, hydrostatic, and endurance testing)
• Dynamic balancing machines, painting and surface treatment lines, and overhead cranes and material handling equipment

Non-ferrous foundry (aluminium, brass, bronze, copper alloys)

• Melting and holding furnaces (induction, crucible, gas/oil fired), degassing and treatment units
• Gravity die casting, low-pressure/high-pressure die casting, and sand casting lines
• Sand plant (mixers, reclamation, core shooters), shot blasting, fettling, and heat treatment furnaces
• Dies, patterns, and tooling

Utilities and infrastructure

• HT/LT panels, transformers, DG sets, capacitor banks, and power quality equipment
• Compressors and air dryers, cooling towers and chillers, and water treatment and effluent systems
• Dust and fume extraction, boilers and pressure vessels, EOT cranes, and lifts

What We’re Looking For

Qualifications and Experience

• Education: E./B. Tech in Mechanical or Electrical Engineering
• Experience: 15-20 years in maintenance, with at least 5 years in a leadership role, ideally in any engineering & manufacturing industry.
• Certifications (preferred): TPM, Lean Six Sigma Green/Black Belt, CMRP or reliability certifications, safety certifications, and automation/PLC exposure.

Skills and Competencies

Technical

• Strong knowledge of electrical systems, machine tools, furnaces, hydraulics, and pneumatics
• Hands-on experience with PLC, SCADA, VFDs, CMMS, and condition monitoring tools
• Understanding of non-ferrous melting metallurgy and its impact on equipment

Managerial

• Strategic thinking and the ability to link maintenance with business goals
• Budgeting, project management, and vendor negotiation
• Data-driven decision-making and structured problem-solving

Behavioral

• Hands-on, available during critical breakdowns, and calm under pressure
• Strong cross-functional collaboration with Production, Quality, Projects, Finance, and EHS
• Change leadership: able to shift a team from reactive firefighting to proactive reliability

Why Armstrong Fluid Technology?

By joining us, you’ll become part of a global community dedicated to pushing the boundaries of fluid-flow technology while upholding Armstrong's commitment to sustainability. You’ll have endless opportunities to learn, grow, and make a significant impact on the world. Together, we'll build tomorrow’s solutions today.