Maintenance (Electrical & Mechanical – Forging Specialist)

Position Title: Manager / Sr. Manager – Maintenance (Electrical & Mechanical – Forging Specialist)
Company Name: Sunstar Precision Forge Ltd.
Location: Greater Noida
Department: Maintenance / Electrical
Reports To: VP – Operations

Role Overview:
The incumbent will lead and manage all maintenance and electrical operations in the forging plant, ensuring maximum equipment reliability, production uptime, and adherence to statutory safety standards. The role demands expertise in both mechanical and electrical maintenance for high-capacity forging and power press machinery.

Key Responsibilities:

• Plan, schedule, and oversee all electrical, mechanical, and hydraulic maintenance activities in the forging plant.
• Execute and manage maintenance for the 12,500 Tons SMS automatic line, including robots, power presses (12,500T, 4000T, 2500T, 1600T), hydraulic presses, conveyors, and auxiliary systems.
• Lead erection and commissioning of mechanical and trimming presses (4500T, 3150T, 6300T, 500T, 1250T Erfurt, 350T Massey, 315T Eumuco, etc.).
• Manage commissioning and maintenance of Inductotherm induction heaters (1250 KW & 2800 KW).
• Ensure preventive, predictive, and breakdown maintenance of forging presses, furnaces, motors, drives, conveyors, and related systems.
• Monitor and maintain HT/LT panels, switchgears, transformers, PLC/SCADA systems, and other electrical infrastructure.
• Lead, train, and motivate a team of technicians and electricians, ensuring skill enhancement and high operational standards.
• Collaborate with production teams to reduce downtime and improve maintenance planning efficiency.
• Maintain detailed records of maintenance schedules, reports, and spare part inventories; coordinate for timely procurement.
• Drive continuous improvement, reliability enhancement, energy optimization, and cost control initiatives.
• Ensure full compliance with EHS (Environment, Health & Safety) and statutory maintenance standards.

Experience:

• 14–16 years of experience in maintenance management within forging or heavy engineering industries.
• Proven expertise with forging machines, hydraulic & mechanical presses, induction heaters, and automated forging lines.
• Strong knowledge of electrical systems, drives, motors, PLC/SCADA, and predictive maintenance practices.
• Demonstrated ability in team leadership, maintenance planning, and reliability improvement initiatives.

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

Key Skills:

• Strong leadership and team management capabilities
• Strategic planning and analytical problem-solving skills
• Proficiency in preventive, predictive, and reliability-based maintenance
• In-depth knowledge of TPM (Total Productive Maintenance) and continuous improvement methodologies
• Excellent communication, coordination, and documentation skills