1. Job Details

Particulars

Details

Job Title

Engineer – GDC Production

Department

Production

Reports To

Production Manager / Plant Head

Location

Manufacturing Plant

Industry

Aluminium Die Casting / Automotive Components

2. Job Purpose

To manage and control day-to-day Gravity Die Casting (GDC) operations to achieve production targets, ensure product quality, maintain process parameters, reduce rejection and improve productivity while complying with safety standards and customer requirements.

3. Roles and Responsibilities

- Plan and execute daily GDC production activities as per the production plan.
- Monitor production targets, cycle time, machine utilization and manpower productivity.
- Ensure proper die preheating, molten metal temperature and pouring parameters.
- Monitor and control casting parameters to ensure consistent product quality.
- Ensure proper degassing, fluxing and molten metal handling practices, wherever applicable.
- Monitor die condition, cooling arrangements, die lubrication and maintenance requirements.
- Coordinate with the Quality Department to control rejection, rework and customer complaints.
- Analyze casting defects such as porosity, shrinkage, cold shuts, misruns and dimensional variations.
- Take corrective and preventive actions to reduce rejection and process abnormalities.
- Ensure operators follow standard operating procedures (SOPs), work instructions and control plans.
- Monitor manpower allocation, operator skill levels and training requirements.
- Ensure availability of raw materials, dies, tools, consumables and other production resources.
- Coordinate with the Maintenance Department to minimize machine and equipment breakdowns.
- Maintain production reports, rejection reports, downtime records and shift handover details.




- Implement 5S, Kaizen, Poka-Yoke and continuous improvement activities.
- Monitor OEE, productivity, cycle time and production loss.
- Ensure proper identification, traceability and segregation of OK, rejected and rework components.
- Ensure compliance with PPE requirements, machine guarding, LOTO and other applicable safety procedures.
- Conduct daily shop-floor inspections and ensure closure of identified abnormalities.
- Support internal audits, customer audits and compliance with applicable IATF 16949 and ISO requirements.
- Ensure proper handling, storage and movement of dies, components and molten metal.
- Prepare and review daily production MIS reports and communicate performance against targets.
- Implement cost-reduction activities to minimize scrap, energy consumption and consumable costs.
- Ensure housekeeping and maintain secure working conditions in the GDC production area.
- Coordinate with Tool Room, Quality, Maintenance and Planning departments to ensure smooth production flow.

4. Key Performance Indicators (KPIs)

KPI

Performance Measurement

Production Achievement

Actual production vs. planned production

Rejection Rate

Percentage of rejected components

OEE

Overall Equipment Effectiveness

Cycle Time

Achievement against standard cycle time

Breakdown

Machine and equipment downtime

Productivity

Components produced per man-hour

Cost Reduction

Scrap,



consumable and process cost savings

Safety

Compliance with safety standards and reduction of incidents

5S

Workplace housekeeping audit score

Customer Quality

Customer complaints and defect recurrence

5. Qualification and Experience

- Qualification: Diploma / BE / B.Tech in Mechanical Engineering, Production Engineering or a relevant discipline.
- Experience: 3–5 years of experience in manufacturing or aluminium Gravity Die Casting operations; experience may vary based on organizational requirements.
- Technical Knowledge: GDC process parameters, aluminium casting defects, die maintenance, quality tools, production planning and process improvement.
- Computer Skills: MS Excel, MS Word, ERP and production MIS reporting.

6. Skills and Competencies

- Production planning and execution.
- Problem-solving and root cause analysis.
- Knowledge of 7 QC Tools, 5 Why Analysis and CAPA.
- Manpower handling and team coordination.
- Quality and process control.
- Safety awareness and risk identification.
- Communication and reporting skills.
- Continuous improvement and cost-reduction mindset.

7. Authority and Accountability

- Ensure adherence to approved production parameters and work instructions.
- Stop production and escalate unsafe conditions or serious quality abnormalities.
- Ensure segregation and identification of nonconforming components.
- Coordinate corrective actions with concerned departments.
- Accountable for production achievement, process quality, rejection control, productivity and workplace safety.

Pay: ₹30,000.00 per month

Benefits:

- Flexible schedule
- Food provided
- Paid sick time
- Provident Fund

Work Location: In person

📌 Engineer GDC (Hosur)
🏢 APJ TECHNOCAST PRIVATE
📍 Hosur