Senior Manager WRM

Position Name:

Role Objective:

To lead, manage, and optimize all electrical and instrumentation systems of the 0.75 MTPA Wire Rod Mill, ensuring uninterrupted production, reliability of equipment, adherence to safety standards, and implementation of continuous improvement initiatives for energy efficiency and cost optimization.

Role Responsibilities:

1. Operations & Reliability

• Ensure reliable operation of power distribution systems, HT/LT motors, transformers, switchgear, and variable frequency drives (VFDs).
  
• Oversee the performance of automation systems (PLC, DCS, HMI, SCADA) for rolling mill process control.
  
• Monitor and maintain instrumentation for speed, tension, temperature, pressure, and flow measurements across the WRM.
  

1. Maintenance & Troubleshooting

• Develop and implement preventive and predictive maintenance schedules.
  
• Lead troubleshooting of electrical drives, motors, PLC/DCS networks, and field instrumentation.
  
• Minimize downtime by ensuring quick restoration and root cause analysis of failures.
  

1. Project Execution & Upgradation

• Lead electrical and automation projects including modernization, revamping, and commissioning of new systems.
  
• Implement energy-saving measures and advanced digitalization (Industry 4.0 / IIoT) solutions in WRM.
  
• Collaborate with OEMs/vendors for technical upgrades.
  

1. Safety & Compliance

• Ensure compliance with statutory requirements, OH&S guidelines, and ISO standards (9001, 14001, 45001, 50001).
  
• Enforce safe work practices including LOTO (Lockout Tagout) procedures and electrical safety audits.
  
• Conduct safety training for the E&I workforce.
  

1. Team Leadership & Coordination

• Lead and mentor a team of engineers, supervisors, and technicians in E&I.
  
• Coordinate with mechanical, operations, and production teams for seamless WRM functioning.
  
• Drive technical training and skill development initiatives within the team.
  

1. Performance Monitoring & Reporting

• Track KPIs such as equipment availability, mean time to repair (MTTR), energy consumption, and system reliability.
  
• Prepare reports on downtime analysis, maintenance performance, and energy efficiency.
  
• Recommend and implement corrective actions for recurring issues.
  

Key Skills & Competencies:

• Strong expertise in Wire Rod Mill E&I systems (motors, drives, control systems, instrumentation).
  
• In-depth knowledge of Siemens / ABB / Allen Bradley PLCs, automation, and process control.
  
• Proficiency in handling HT/LT power systems, VFDs, and digital drives.
  
• Exposure to mill automation, loopers, pinch rolls, laying head, shears, and coil handling systems.
  
• Excellent leadership, decision-making, and problem-solving skills.
  
• Strong focus on safety, reliability, and cost optimization.
  

Qualifications & Experience:

• B.E./B.Tech in Electrical / Instrumentation Engineering.

• 12–15 years of relevant experience in E&I in Wire Rod Mill.
• Experience in handling large-scale automation projects and revamping initiatives.
  
• Prior exposure to managerial/team leadership role is essential.