Assistant Foundry Manager

We are looking for a proactive and experienced Assistant Manager - Foundry Maintenance to spearhead our maintenance operations at Rapsri Engineering Products Co Pvt Ltd. This pivotal role involves ensuring the optimal performance and reliability of our state-of-the-art foundry equipment, including Inductotherm Induction Furnaces, Rautomead Continuous Casting Machines, and related accessories. The ideal candidate will lead a team of maintenance personnel, drive preventive and breakdown maintenance activities, manage spare parts inventory, and implement strategies to minimize downtime and improve equipment uptime. You will play a crucial role in enhancing our TPM initiatives, conducting root cause analysis, and controlling maintenance costs, all within a safe and compliant work environment. Your expertise will be instrumental in supporting our production of high-quality copper, brass, and bronze components for global OEMs. If you are passionate about equipment maintenance, have a strong background in foundry operations, and thrive in a dynamic manufacturing setting, we encourage you to apply and contribute to our continued success. This role demands a hands-on approach, excellent problem-solving skills, and the ability to work collaboratively across departments to achieve operational excellence.

Responsibilities:

Preventive and Breakdown Maintenance

• Develop, implement, and manage a comprehensive preventive maintenance (PM) program for all foundry equipment, including Inductotherm Induction Furnaces, Rautomead Continuous Casting Machines, and related accessories.
• Oversee and coordinate breakdown maintenance activities, ensuring timely and effective repairs to minimize equipment downtime.
• Conduct regular inspections of equipment to identify potential issues and proactively address them to prevent breakdowns.
• Maintain detailed records of all maintenance activities, including PM schedules, breakdown repairs, and equipment performance data.
• Collaborate with the production team to schedule maintenance activities that minimize disruption to production schedules.
• Ensure compliance with safety regulations and company policies during all maintenance activities.

Equipment Reliability and Uptime Optimization

• Analyze equipment performance data to identify areas for improvement and implement strategies to enhance equipment reliability and uptime.
• Conduct root cause analysis (RCA) of equipment failures to identify underlying causes and implement corrective actions to prevent recurrence.
• Implement reliability engineering principles and practices to improve equipment design, maintenance procedures, and operating practices.
• Monitor equipment condition using techniques such as vibration analysis, thermography, and oil analysis to detect potential problems early.
• Develop and implement corrective actions to address equipment failures and improve overall equipment effectiveness (OEE).
• Work with vendors and suppliers to source high-quality replacement parts and ensure timely delivery.

Spares Inventory Management

• Manage the inventory of spare parts for all foundry equipment, ensuring adequate stock levels to support maintenance activities.
• Develop and implement a spares inventory management system to track inventory levels, usage, and reorder points.
• Identify and source spare parts from reliable vendors, negotiating favorable pricing and delivery terms.
• Conduct regular audits of the spares inventory to ensure accuracy and identify obsolete or excess inventory.
• Implement strategies to optimize spares inventory levels, reducing carrying costs while ensuring availability of critical parts.
• Collaborate with the purchasing department to streamline the procurement process for spare parts.

Maintenance Team Supervision and Development

• Supervise and mentor a team of maintenance technicians, providing guidance, training, and support to ensure their success.
• Schedule and assign work to maintenance technicians, ensuring efficient utilization of resources and timely completion of tasks.
• Conduct performance evaluations of maintenance technicians, providing feedback and identifying areas for improvement.
• Develop and implement training programs to enhance the skills and knowledge of maintenance technicians.
• Promote a culture of safety within the maintenance team, ensuring compliance with safety regulations and company policies.
• Foster teamwork and collaboration within the maintenance team and with other departments.

Maintenance Budgeting and Cost Control

• Develop and manage the maintenance budget, ensuring efficient allocation of resources and cost-effective maintenance practices.
• Track maintenance expenses and identify opportunities to reduce costs without compromising equipment reliability.
• Negotiate contracts with vendors and suppliers to obtain favorable pricing for maintenance services and spare parts.
• Implement cost control measures to minimize waste and optimize resource utilization.
• Prepare regular reports on maintenance costs, performance, and key metrics.
• Monitor and control the consumption of consumables used in the foundry operations.

General Expectations and Past Experiences:

• Proven experience in foundry maintenance, with a strong understanding of Inductotherm Induction Furnaces and Rautomead Continuous Casting Machines.
• Demonstrated ability to lead and manage a maintenance team, fostering a culture of safety, teamwork, and continuous improvement.
• Expertise in preventive maintenance (PM) program development and implementation, with a focus on optimizing equipment uptime and reliability.
• Proficiency in root cause analysis (RCA) methodologies and corrective actions implementation to address equipment failures effectively.
• Strong knowledge of spares inventory management and optimization, ensuring availability of critical parts while minimizing carrying costs.
• Excellent electrical troubleshooting and repair skills, with experience in PLC programming and hydraulic systems maintenance.
• Experience in maintenance budgeting and cost control, with a track record of reducing maintenance expenses without compromising equipment reliability.