Job Description
Principal Duties and Responsibilities
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- Direct, plan, and coordinate all maintenance activities to support safe and efficient foundry operations.
- Ensure maximum uptime and reliability of critical foundry equipment including melting furnaces, molding lines, core machines, sand systems, shakeout equipment, conveyors, grinders, dust collection systems, and material handling equipment.
- Develop and execute predictive, preventive, and corrective maintenance programs to improve equipment reliability and reduce unplanned downtime.
- Partner with Production, Engineering, Quality, and Safety teams to identify and eliminate chronic equipment issues impacting productivity and quality.
- Lead root cause analysis investigations for major equipment failures and implement corrective actions.
- Manage maintenance support for plant shutdowns, outages, capital projects, equipment installations, and commissioning activities.
- Oversee contractor activities to ensure compliance with company safety standards and project requirements.
- Monitor and improve maintenance KPIs including downtime, MTBF (Mean Time Between Failures), PM completion rates, maintenance costs, and equipment availability.
- Ensure compliance with environmental, safety, and regulatory requirements related to foundry operations.
- Develop and maintain spare parts strategies for critical foundry equipment to minimize production interruptions.
- Support continuous improvement initiatives including Lean Manufacturing, TPM (Total Productive Maintenance), and reliability-centered maintenance practices.
- Train, coach, and develop maintenance supervisors and technicians to enhance technical capabilities and leadership skills.
- Support energy management initiatives related to compressed air, natural gas, electrical systems, melting operations, and utility consumption.
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Additional Knowledge, Skill, and Ability Requirement
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- Strong knowledge of foundry processes including melting, molding, core making, pouring, shakeout, finishing, and material handling systems
- Working knowledge of electrical, hydraulic, pneumatic, mechanical, and PLC-controlled manufacturing equipment
- Experience troubleshooting induction furnaces, dust collection systems, air compressors, cooling systems, conveyors, robotics, and automated production equipment
- Knowledge of predictive maintenance technologies including vibration analysis, thermography, oil analysis, and condition monitoring
- Understanding of OSHA requirements, lockout/tagout procedures, machine guarding, and industrial safety practices
- Experience with CMMS systems and maintenance planning software
- Ability to analyze maintenance data and develop strategies to improve equipment performance and reliability
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Additional Education and Experience Requirements
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- Experience in a foundry, metal casting, heavy manufacturing, steel, aluminum, iron, or similar industrial environment strongly preferred
- Minimum 5-8 years of progressive maintenance leadership experience in a manufacturing or foundry setting
- Demonstrated experience managing maintenance budgets, capital projects, and reliability improvement initiatives.
- Experience supervising multi-craft maintenance teams including electricians, millwrights, mechanics, and controls technician.
- Experience with automated manufacturing systems, robotics, PLCs, and industrial controls preferred.
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