1. Casting Design & Methoding

- Optimize gating systems: Design effective gating, riser, runner, and feeding systems for pump casings, impellers, and valve bodies.
- Utilize simulation tools: Run and analyze casting solidification simulations using software like MAGMA5 or ProCAST to predict and eliminate hotspots, shrinkage, and porosity.
- Pattern & Die development: Collaborate with the pattern shop using CAD software like Creo and AutoCAD to engineer pattern layouts, core boxes, and match plates.

2. Process & Quality Optimization

- Minimize defect rates: Drive root cause analysis (RCA) and corrective actions (CAPA) for casting defects such as blowholes, sand inclusion, and cracks.
- Improve casting yield: Implement methoding changes to increase the ratio of poured metal weight to finished casting weight, directly reducing melting and energy costs.
- Moulding process control: Align methoding designs with the foundry's moulding loops, specifically for Alpha-set, sand systems, and investment casting operations. [

3. Cross-Functional Operations





- NPD (New Product Development): Participate in trials for new pump and valve models, creating method sheets from initial drawings to final pilot runs.
- Standardization: Document and update Methoding Standard Operating Procedures (SOPs) and control checklists for the shop floor.
- Continuous Improvement: Support TPM, Kaizen, and 5S initiatives to enhance overall equipment effectiveness (OEE) and shop floor safety.

Technical & Behavioral Skills

- Casting Knowledge: In-depth understanding of liquid metal fluid flow, thermal solidification, and the metallurgy of steel, cast iron, and alloy castings.
- Software Proficiency: Hands-on experience with CAD tools (Creo, AutoCAD) and casting simulation software.
- ERP Integration: Familiarity with creating and managing routing data or Bill of Materials (BOM) in SAP PP.
- Problem Solving: Mastery of quality tools such as 8D analysis, Fishbone diagrams, and FMEA.

📌 Senior Manager (Pune)
🏢 Kirloskar Brothers
📍 Pune