Role & responsibilities

Key Responsibilities

1. Refractory Planning & Management

- Prepare and implement annual and monthly refractory maintenance plans for all SMS units.
- Schedule relining, patching, fettling, and gunning operations in coordination with production and maintenance teams.
- Ensure optimum utilization of monolithic, shaped, and unshaped refractories.
- Track and analyze refractory life, wear rate, and consumption across all SMS areas.
- Identify causes for premature refractory wear or failure and initiate corrective/preventive actions.
- Optimize slag composition, metal temperature, and operating parameters to enhance refractory performance.
- Benchmark refractory KPIs such as life, cost per ton, and specific consumption against industry standards.
- Lead trials and evaluate current refractory materials and vendors.

1. Performance Monitoring & Optimization

- Review refractory consumption data regularly and prepare cost and performance reports.
- Implement best practices and standard operating procedures (SOPs) for refractory installation, drying, and maintenance.
- Monitor drying and preheating cycles for ladles and tundishes.
- Maintain furnace lining charts, ladle life records, and tundish refractory history sheets.
- Conduct root cause analysis (RCA) for refractory failures and drive improvements.

1. Material Procurement & Vendor Coordination

- Prepare monthly refractory demand forecasts based on production schedules.
- Coordinate with procurement and stores to ensure timely availability of refractory materials.
- Conduct vendor evaluation, technical audits, and performance reviews.
- Ensure quality inspection of refractory materials at receipt and during installation.

1. Installation, Maintenance & Supervision

- Supervise refractory lining, gunning, and fettling activities in EAF, LF, VD, CCM, ladles, and tundishes.
- Ensure adherence to design drawings,



refractories layout, and SOPs during installation.
- Coordinate with mechanical, production, and safety teams during shutdowns.
- Implement refractory consumption cost control programs ensuring optimal expenditure per ton of liquid steel.
- Monitor inventory levels to avoid shortages or overstocking.

1. Safety & Compliance

- Ensure safe working practices during refractory installation, handling, and hot repair jobs.
- Conduct safety audits, toolbox talks, and hazard identification (HAZOP) for refractory operations.
- Enforce compliance with company safety policies and environmental regulations.
- Maintain housekeeping and 5S standards in refractory storage and work areas.

1. Documentation & Reporting

- Maintain comprehensive refractory life, consumption, and performance records for all SMS units.
- Prepare and submit daily, weekly, and monthly performance and consumption reports.
- Support audits, ISO documentation, and technical reviews.
- Maintain detailed refractory consumption and life cycle analysis data.

1. Team Leadership & Development

- Lead a team of engineers, supervisors, and contractors to ensure effective refractory operations.
- Allocate work responsibilities, monitor progress, and ensure safety compliance.
- Conduct training and skill development programs for refractory team members.
- Promote teamwork, accountability, and continuous improvement culture.

Preferred candidate profile Qualifications & Experience

- B.E./B.Tech in Ceramic, Metallurgical, Mechanical, or related Engineering discipline.
- Manager: 10 to 14 years of experience in refractory management at Steel Melting Shop or integrated steel plants.
- Senior Manager: 14 to 18 years of experience with proven expertise in refractory performance optimization across EAF, LF, VD, CCM operations.
- Industry experience in Integrated Steel Plant, Alloy Steel, or Ferro Alloy sectors preferred.

📌 Senior Manager / Manager Refractory (Steel Melting Shop) (Pune)
🏢 Sarthee Consultancy
📍 Pune