Company Overview

KISCO Castings India Limited is a leading specialty steel manufacturer with integrated operations across steel melting, forging, rolling, heat treatment, bright bars, and machining. KISCO serves critical industries including defence, railways, energy, heavy engineering, and OEMs globally, with a strong focus on reliability, safety, and technology-driven manufacturing excellence.

Salary offered - 20 - 30 LPA

Role Purpose

The GM - Maintenance is a plant-critical leadership role, responsible for ensuring high asset reliability, minimal breakdowns, strong safety performance, and disciplined preventive & predictive maintenance systems across all electrical, mechanical, and utility assets.

This role is not firefighting-oriented. It is designed for a leader who builds robust systems, reliability and safety culture, and technology-enabled maintenance practices, while remaining closely connected to the shopfloor.

Key Responsibilities

1. Maintenance Strategy & Leadership

- Define and execute an integrated preventive and predictive maintenance strategy across steel melting, forging, heat treatment, cranes, and utilities.

- Lead a combined electrical + mechanical + utility maintenance team, ensuring clear accountability, skill development, and strong discipline.

- Build second-line capability and reduce single-point dependencies within the maintenance organization.

2. Asset Reliability & Breakdown Reduction

- Own plant-wide breakdown reduction, with a sharp focus on steel melting operations and EOT cranes, which are current critical assets.

- Drive root cause analysis (RCA) for all major failures using structured tools (5-Why, FMEA, fishbone) and ensure permanent corrective actions.

- Monitor and improve MTBF, MTTR, downtime hours, and maintenance cost trends.

3. Electrical Systems, Power Quality & Automation

- Oversee maintenance of transformers, substations, panels, drives, motors, furnaces, cranes, and power distribution systems.

- Ensure power quality monitoring and stability, maintaining KISCO's strong performance in this area.

- Provide leadership on PLCs, automation, and control systems through team guidance and vendor coordination (hands-on coding not mandatory).

4. Mechanical Systems & Predictive Maintenance

- Ensure reliable operation of furnaces, rolling mills, forging equipment, hydraulic and pneumatic systems, cranes, and rotating equipment.

- Effectively utilize and further strengthen predictive maintenance tools such as vibration analysis, thermography, oil analysis, and condition monitoring.

- Encourage investment in advanced reliability tools and technologies, provided they are effectively implemented and used.

5. Shutdown Planning & Project Coordination

- Plan and execute monthly plant shutdowns in close coordination with PPC and Projects teams.

- Own maintenance execution during shutdowns with a strong focus on safety, quality, and timeline adherence.

- Support new project commissioning and stabilization, ensuring smooth transition from project phase to steady-state operations.

6. Safety Ownership

- Act as a strong safety leader, with zero tolerance for unsafe practices.

- Enforce electrical safety, crane safety, LOTO, confined space, and high-risk maintenance procedures.

- Empower teams to stop work where safety is compromised and embed safety into daily maintenance behavior.

7. Cost Control, Spares & Inventory

- Drive maintenance cost optimization without compromising asset health or safety.

- Focus on improving spares inventory turns, critical spares identification, and rationalization.

- Commercial negotiations and purchasing will be handled by the Commercial GM; however, technical specifications and lifecycle decisions remain with this role.

8. Authority & Decision Rights

Full authority to:

- Approve planned shutdowns (in coordination with PPC)

- Approve spares procurement and AMC renewals

- Approve replacement capex for end-of-life equipment

- New project capex approvals remain with MD.

Key Performance Indicators (KPIs)

- Reduction in unplanned breakdowns and downtime

- Maintenance cost control and inventory turns

- Crane availability and safety performance

- Effectiveness of preventive & predictive maintenance

- Safety metrics (zero serious incidents)

- Stabilization of new equipment/projects

Candidate Profile

Qualifications & Experience

- BE/B.Tech in Mechanical / Electrical / Electrical & Mechanical Engineering

- 18+ years of experience in maintenance roles within heavy manufacturing (preferably steel)

- Proven experience managing both electrical and mechanical maintenance

- Exposure to steel plants preferred; strong heavy manufacturing experience acceptable

Leadership & Working Style

- 50% shopfloor engagement / 50% system building

- Strong team leader with hands-on credibility

- Comfortable working directly with MD and cross-functional leaders

Language & Communication

Hindi essential; Punjabi desirable

English & Hindi for white-collar coordination and reporting