Roles and Responsibilities of a Costing Assistant – Aluminium Sand Casting Factory

1. Cost Estimation

Prepare cost estimates for current aluminium sand casting components based on customer drawings and specifications.

Calculate material, process, machining, and finishing costs.

Estimate moulding, melting, fettling, machining, heat treatment, and inspection costs.

Support the quotation team by providing accurate cost sheets.

2. Raw Material Costing

Calculate aluminium alloy consumption per casting.

Consider melting losses, gating and riser weight, and yield percentage.

Monitor aluminium ingot, scrap, and alloying element prices.

Update material cost databases periodically.

3. Process Cost Analysis

Calculate process-wise costs including:

Sand moulding

Core making

Melting

Pouring

Shakeout

Fettling

Heat treatment

Machining

Surface finishing

Packing

Identify major cost contributors and recommend cost-saving opportunities.

4. Labour Cost Calculation

Estimate direct labour hours for each manufacturing operation.

Calculate labour costs based on standard rates.

Compare standard labour costs with actual production data.

5. Machine Costing

Calculate machine hour rates for:

Melting furnace

Sand mixer

Core shooter

Shot blasting

CNC machines

Drilling and tapping machines

Include electricity, maintenance, depreciation, and operator costs.

6. BOM (Bill of Materials) Preparation

Prepare and maintain Bills of Materials for all products.

Update BOMs based on engineering changes.

Verify material quantities with design and production departments.

7. Cost Sheet Preparation

Prepare detailed product cost sheets including:





Raw material

Consumables

Labour

Machine cost

Tooling cost

Overheads

Packing

Transportation (if applicable)

Profit margin

Maintain historical costing records.

8. Production Data Collection

Collect production data from the shop floor.

Record cycle times and process efficiencies.

Monitor casting yield and rejection rates.

Analyze production losses affecting product cost.

9. Rejection and Scrap Cost Analysis

Calculate the cost impact of casting rejections.

Monitor scrap generation and recovery.

Identify recurring causes of rejection affecting profitability.

10. Inventory Cost Monitoring

Monitor inventory valuation of:

Aluminium ingots

Return scrap

Sand

Chemicals

Consumables

Coordinate with stores and accounts for inventory reconciliation.

11. Vendor Cost Comparison

Compare quotations from suppliers.

Analyze purchased component costs.

Support procurement in vendor selection based on cost competitiveness.

12. Cost Reduction Activities

Identify opportunities for:

Yield improvement

Scrap reduction

Energy savings

Process optimization

Material substitution

Assist in implementing cost-saving initiatives.

13. Coordination

Coordinate with:

Production

Design

Purchase

Quality

Sales

Finance





Gather necessary information for accurate costing.

14. Reporting

Prepare reports on:

Product-wise costing

Monthly cost analysis

Material price variations

Cost variances

Profitability analysis

Cost reduction initiatives

Key Skills Required

Maintain master data for materials, routing, and standard costs.

Generate costing and variance reports.

Knowledge of aluminium sand casting processes.

Understanding of costing principles and manufacturing economics.

Ability to read engineering drawings.

Knowledge of Bills of Materials (BOM) and process routing.

Strong analytical and numerical skills.

Proficiency in Microsoft Excel (Pivot Tables, VLOOKUP/XLOOKUP, formulas, charts).

Familiarity with ERP software.

Good communication and coordination skills.

Attention to detail and accuracy.

Educational Qualification

B.Com / BBA / MBA (Finance) for costing-focused roles, or

Diploma/B.E. in Mechanical, Production, or Metallurgical Engineering for technical costing roles.

Additional certification in Cost Accounting or ERP systems is advantageous.

Key Performance Indicators (KPIs)

Accuracy of cost estimates.

Quotation turnaround time.

Standard vs. actual cost variance.

Material yield improvement.

Reduction in scrap and rejection costs.

Timely preparation of BOMs and cost sheets.

Accuracy of ERP costing data.

Contribution to cost reduction initiatives.

On-time submission of costing reports.

Support for achieving target product margins.

Pay: ₹30,000.00 - ₹35,000.00 per month

Benefits:

- Provident Fund

Work Location: In person

📌 Costing Assistant (Gummidipoondi)
🏢 SRI BALAJI CASTINGS
📍 Gummidipoondi