BEHARI LAL ENGINEERING LIMITED Alloy & Steel Castings

1. Position Summary The Method Engineer is responsible for the complete methoding of steel and alloy steel castings produced on the no-bake (chemically bonded) sand system, covering casting weights from 500 kg to 25 MT. The role owns the technical design of gating, feeding and risering systems, pattern and core-box requirements, and yield optimisation for a product mix that includes valve and pump bodies, wear parts and general engineering castings. The engineer drives first-time-right development of new castings, reduces methoding-related rejections, and coordinates casting simulation (currently outsourced) with the objective of progressively building this capability in-house.
2. Key Responsibilities Methoding, Gating & Feeding Design

Design gating, running and feeding (riser / chill / padding) systems for heavy steel and alloy castings (500 kg

25 MT) using modulus and solidification principles.

Determine number, size and location of risers, chills, insulating / exothermic sleeves and cover material to ensure directional solidification and sound castings.

Optimise pouring parameters pouring temperature guidance, pouring time, sprue / ingate ratios in coordination with the melting and pouring teams.

Pattern & Core-Box Development

¢ Prepare pattern and core-box layouts, defining shrinkage / contraction allowances, machining allowances,

draft, core prints and parting arrangement for the no-bake process.

¢ Coordinate pattern manufacture with in-house and external pattern shops; review, trial and approve first-off patterns and core boxes.

¢ Maintain pattern equipment records, revisions and physical condition to ensure dimensional accuracy of moulds and cores.

Casting Simulation & Yield Optimisation

¢ Prepare inputs and coordinate solidification / mould-filling simulation with the outsourced simulation partner;

interpret results and iterate the method to eliminate shrinkage porosity, cold shuts and inclusions before pattern release.





¢ Support the phased development of in-house simulation capability defining requirements, validating results against shop-floor outcomes and building standard practice.

¢ Drive casting yield improvement and accurate estimation of casting, feeder and pattern weights for costing and enquiry response.

No-Bake Process, Method Sheets & Standardisation

Method Engineer (Casting Shop)

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BEHARI LAL ENGINEERING LIMITED Alloy & Steel Castings ¢ Specify mould and core parameters for the no-bake system box sizes, mould thickness, hardness, coating and closing requirements.

¢ Prepare and maintain method sheets, methoding drawings and process route cards, and standardise proven methods across similar part families.

Rejection Analysis & Continuous Improvement

¢ Analyse casting defects (shrinkage, sand / slag inclusion, blowholes, cracks, mis-run, dimensional) and lead root-cause analysis and corrective / preventive actions for methoding-related rejections.

¢ Track methoding KPIs and drive measurable reduction in rejection and rework.

New Product Development & Coordination

¢ Lead recent casting development from customer drawing to approved first article, including feasibility,

methoding, sampling and validation.

¢ Interface with pattern shop, moulding, melting, fettling and quality functions, and provide technical support to customers on castability, methoding and design-for-manufacture queries.

¢ Ensure methoding complies with applicable material and casting standards (e.g. ASTM, IS, EN) and internal quality requirements.

- Qualifications & Experience

¢ Education: Diploma / B.E. / B.Tech in Metallurgy, Mechanical or Foundry Technology (NIFFT or equivalent preferred).

¢ Experience:



Minimum 5 years of methoding / process engineering experience in a steel or alloy steel foundry,

preferably on the no-bake sand system and with heavy castings.

¢ Domain: Demonstrated hands-on methoding of medium-to-heavy castings; experience up to the 25 MT range is a solid advantage.

- Technical Skills & Competencies

¢ Simulation: Working knowledge of casting simulation software (e.g. MAGMASOFT, ProCAST, AutoCAST or

SOLIDCast) essential.

¢ CAD: Proficiency in CAD tools (e.g. AutoCAD, SolidWorks or Creo) for methoding layouts and pattern drawings essential.

¢ Methoding: Strong command of methoding fundamentals gating and risering design, modulus method,

feeding distance, Chvorinovs rule and directional solidification.

¢ Process: Sound understanding of the no-bake (furan / alkaline-phenolic) sand system and its influence on casting quality.

¢ Materials: Familiarity with carbon, alloy and stainless steel grades and relevant casting standards (ASTM / IS /

EN).

- Desirable Attributes

¢ Exposure to valve / pump body and wear-part castings.

¢ Experience setting up or bringing simulation in-house.

¢ Knowledge of casting cost estimation and yield benchmarking.

- Behavioural Competencies

¢ Analytical and structured problem-solving with a data-driven approach to defect reduction.

¢ Strong cross-functional coordination and clear technical communication.

¢ Ownership, accountability and a continuous-improvement mindset.

- Key Performance Indicators

¢ Casting yield improvement (%) across the assigned part mix.

Method Engineer (Casting Shop)

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BEHARI LAL ENGINEERING LIMITED Alloy & Steel Castings

¢ Reduction in methoding-related rejection and rework (%).

¢ Methoding turnaround time for new enquiries and developments.

¢ First-time-right rate on new casting developments.

¢ Pattern / method development lead time.

This outlines the primary duties of the role and is not exhaustive; responsibilities may evolve with organisational needs.

Method Engineer (Casting Shop)

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📌 Method Engineer (Mandi Gobindgarh)
🏢 Behari Lal Engineering
📍 Mandi Gobindgarh