Role & responsibilities

To lead and manage the Aluminium Foundry operations with overall responsibility for production, quality, process control, productivity, cost optimisation, safety, manpower and operational excellence, ensuring consistent production of high-quality aluminium billets/alloy products in line with business and customer requirements.

Key Responsibilities

- Lead end-to-end Aluminium Foundry operations, including melting, alloying, casting, homogenizing and related processes.
- Ensure achievement of production targets, yield, productivity and quality parameters as per the production plan.
- Monitor and optimise melting practices, furnace operations, alloy composition, degassing, filtration, casting parameters and billet quality.
- Ensure adherence to approved SOPs, process parameters and quality standards across foundry operations.
- Drive reduction in metal loss, dross generation, rejection, rework and energy consumption.
- Monitor and control raw material, alloying elements, scrap and return metal utilisation to optimise metal recovery and cost.
- Coordinate closely with Quality, Maintenance, PPC, Stores, Purchase and downstream manufacturing functions for smooth operations.
- Analyse production and process data and implement corrective and preventive actions to improve OEE, yield and operational efficiency.
- Drive continuous improvement, Kaizen, 5S, Lean Manufacturing and cost-reduction initiatives within the foundry.
- Ensure effective preventive maintenance and timely resolution of equipment-related issues in coordination with the Maintenance team.




- Ensure strict compliance with EHS requirements, statutory regulations, fire safety and safe operating practices.
- Lead, develop and manage engineers, supervisors, operators and contract manpower and ensure optimum manpower utilisation.
- Conduct regular performance reviews and develop the technical capabilities of the foundry team through training and skill development.
- Maintain appropriate MIS, production reports, process records and KPI dashboards for management review.
- Support new product/alloy development, process trials and customer-specific metallurgical requirements.
- Work with the Quality and Technical teams to investigate metallurgical defects, casting defects and customer complaints and implement sustainable corrective actions.
- Ensure readiness for internal, customer and external audits and compliance with applicable quality and environmental standards.
- Drive a culture of ownership, discipline, accountability, safety and continuous improvement within the foundry.

Key Performance Indicators

- Production volume and plan adherence
- Metal recovery / yield
- Furnace and casting productivity
- Billet quality and rejection levels
- Dross and metal-loss reduction




- Energy consumption per MT
- OEE and equipment utilisation
- Cost per MT
- Customer complaints / quality performance
- Safety performance
- Manpower productivity
- Continuous improvement / cost-saving initiatives

Qualification

- B.E./B.Tech in Metallurgy / Mechanical / Production Engineering or equivalent qualification.
- Additional qualification in Metallurgy / Foundry Technology will be an advantage.

Experience

- 1218 years of relevant experience in Aluminium Foundry / Non-Ferrous Foundry operations.
- Solid hands-on experience in Aluminium melting, alloying, billet casting and foundry process control.
- Experience in managing medium to large-scale foundry operations with significant manpower and production responsibility.
- Strong exposure to process improvement, yield optimisation, quality management and cost reduction.
- Experience in a manufacturing environment with integrated Aluminium operations will be preferred.

Desired Competencies

- Strong technical and operational expertise in Aluminium Foundry.
- Sound understanding of Aluminium alloys, metallurgy and casting processes.
- Strong analytical and problem-solving capability.
- Production planning and execution skills.
- Leadership and people-management capability.
- Cost-conscious and results-oriented approach.
- Strong cross-functional coordination skills.
- Ability to work in a high-volume, target-driven manufacturing environment.
- Strong focus on safety, quality and continuous improvement.

📌 Senior Manager - Foundry (Bhiwadi)
🏢 Jindal Aluminium
📍 Bhiwadi