We are seeking a highly experienced, hands-on foundry skilled to support the Foundry Head in managing day-to-day operations of a captive engineering foundry. The successful candidate will possess deep practical knowledge of alloy cast iron and steel castings, particularly high-chrome white iron, Ni-Hard, manganese steel, and other wear-resistant grades used in ash handling, coal handling, mining, cement, steel, and power plant applications.
The role demands strong technical expertise coupled with excellent shop-floor leadership and problem-solving ability.
Role & responsibilities
Production
* Assist in planning and execution of daily foundry production.
* Ensure achievement of production targets with optimum yield and productivity.
* Supervise melting, moulding, pouring, shakeout, fettling and finishing operations.
* Monitor utilisation of furnaces, moulding lines and manpower.
* Improve productivity while reducing rejection and manufacturing costs.
Metallurgy & Process Control
* Develop and optimise melting practices for:
* High Chrome White Iron
* Ni-Hard Grades IIV
* Austenitic Manganese Steel
* SG Iron
* Grey Iron
* Alloy Steel
* Carbon Steel
* Heat-resistant and abrasion-resistant alloys
* Control charge mix and alloy additions.
* Monitor carbon, silicon and alloy chemistry.
* Establish process controls for consistent metallurgical quality.
* Work closely with laboratory personnel on spectrometer analysis and process corrections.
Quality Assurance
* Reduce casting rejection through process improvements.
* Investigate defects including:
* Shrinkage
* Gas porosity
* Sand inclusion
* Blow holes
* Cold shuts
* Misruns
* Cracks
* Hardness variation
* Carbide segregation
* Ensure dimensional accuracy and metallurgical compliance.
* Support customer inspections and audits.
Pattern & Methoding
* Review gating and risering systems.
* Optimise casting yield.
* Improve solidification characteristics.
* Coordinate with pattern shop and design engineers.
Heat Treatment
* Develop and monitor heat treatment cycles.
* Ensure hardness and mechanical properties meet specifications.
* Optimise stress relieving, annealing, normalising and quenching processes where applicable.
Continuous Improvement
* Improve metal recovery and casting yield.
* Reduce melting power consumption.
* Improve furnace campaign life.
* Reduce consumable costs.
* Implement Lean Manufacturing and 5S practices.
* Drive root-cause analysis and corrective actions.
Team Leadership
* Guide supervisors and shop-floor engineers.
* Train production personnel in foundry best practices.
* Develop standard operating procedures.
* Promote discipline and teamwork.
Safety & Environment
* Ensure compliance with all statutory safety requirements.
* Improve safe molten metal handling practices.
* Monitor PPE compliance.
* Maintain housekeeping standards.
* Support environmental compliance initiatives.
Preferred candidate profile
15 to 25 years in ferrous foundries, with significant experience in wear-resistant alloy castings.
* B.E./B.Tech. in Metallurgical Engineering, Mechanical Engineering or Production Engineering.
* Degree/Diploma in Foundry Technology or Metallurgy will be an added advantage.
The candidate should possess hands-on experience in: