Job Description:

JOB DESCRIPTION

Position: Electrical Maintenance Engineer / Sr. Engineer – Electrical Maintenance
Department: Maintenance – Casting / Foundry
Industry: Automotive Components / Foundry
Location: IMT Manesar, Gurugram, Haryana
Company: Munjal Group / Munjal Kiriu
Reporting To: Manager / Head – Maintenance

Job Objective

Responsible for ensuring maximum availability and reliability of electrical systems, casting/foundry equipment and production utilities through preventive, predictive and breakdown maintenance. The role will focus on minimizing machine downtime, improving equipment reliability and ensuring safe and efficient operation of electrical installations.

Key Responsibilities

1. Electrical Maintenance – Foundry

• Handle electrical maintenance of casting/foundry production equipment and associated utilities.
• Troubleshoot electrical breakdowns and restore equipment within minimum possible time.
• Carry out preventive and predictive maintenance as per maintenance schedules.
• Maintain electrical panels, MCCs, PCCs, control panels, transformers and distribution systems.
• Troubleshoot motors, starters, contactors, relays, sensors, encoders and electrical circuits.
• Maintain industrial lighting, power distribution and earthing systems.

2. Induction Furnace Maintenance

• Electrical maintenance of Inductotherm / induction furnaces, furnace control systems and associated equipment.
• Troubleshoot furnace electrical and control-related breakdowns.
• Monitor furnace parameters, power supply, cooling systems and electrical protection systems.
• Coordinate with OEM/service providers for major furnace breakdowns and technical issues.

3. Automation & Controls

• Troubleshoot PLC, HMI, VFD/AC drives, sensors, proximity switches and control circuits.
• Knowledge of Siemens/Allen-Bradley or equivalent PLC systems will be preferred.
• Diagnose PLC I/O and communication-related faults.
• Support automation improvement and machine modification activities.

4. Casting Equipment

• Maintenance of electrical systems for:
  • DISA / automatic moulding lines
  • Sand plant and sand preparation equipment
  • Shot blasting machines
  • Fettling equipment
  • Conveyors
  • Material handling systems
  • Compressors and cooling systems
  • Machining-related electrical equipment

5. Preventive & Breakdown Maintenance

• Prepare and execute PM schedules for electrical equipment.
• Analyze recurring breakdowns and implement permanent corrective actions.
• Conduct breakdown analysis using RCA / 5-Why / Fishbone methodology.
• Maintain maintenance history, breakdown records and equipment-wise data.
• Identify critical spares and maintain optimum inventory levels.

6. Energy & Reliability Improvement

• Monitor electrical energy consumption and identify energy-saving opportunities.
• Improve equipment MTBF and reduce MTTR.
• Support TPM, Kaizen, OEE and continuous improvement initiatives.
• Implement electrical modification and improvement projects to improve machine reliability.

7. Safety & Compliance

• Ensure compliance with electrical safety standards and plant safety procedures.
• Follow LOTO procedures during maintenance activities.
• Ensure proper earthing, electrical protection and panel safety.
• Conduct periodic inspection of electrical installations.
• Maintain required maintenance and safety documentation.

Required Technical Skills

• Strong knowledge of industrial electrical maintenance.
• Experience in casting/foundry electrical maintenance preferred.
• Knowledge of induction furnace electrical systems.
• Hands-on experience with PLC, HMI and VFD.
• Knowledge of MCC, PCC, control panels and electrical distribution.
• Knowledge of motors, drives, sensors and industrial automation.
• Ability to read electrical drawings and control schematics.
• Knowledge of preventive and breakdown maintenance.
• Good troubleshooting and root-cause-analysis skills.
• Knowledge of TPM, Kaizen, OEE and maintenance KPIs.

Education

Diploma / B.E. / B.Tech – Electrical / Electrical & Electronics Engineering

Experience

4–8 years of relevant experience in electrical maintenance in automotive, foundry, casting, steel, forging or engineering manufacturing industries.

Candidates having hands-on experience with induction furnaces, DISA moulding lines, sand plants and PLC/VFD systems will be preferred.

Key Performance Indicators (KPIs)

• Machine availability
• Reduction in electrical breakdowns
• MTBF improvement
• MTTR reduction
• PM compliance
• Electrical energy consumption
• Maintenance cost reduction
• Zero major electrical safety incidents
• Spare-parts optimization
• OEE improvement

Preferred Candidate Profile

Candidate should be hands-on, technically strong and comfortable working in a high-volume automotive casting/foundry environment. Experience with modern foundry automation, induction furnaces and PLC-based equipment will be an advantage.

Work Location: IMT Manesar, Gurugram, Haryana.