Melting operations

- Plan and run daily melting to match the moulding and pouring schedule, by grade, quantity and timing.
- Operate and supervise induction furnaces (and cupola/arc furnaces where installed), including charging, melting, superheating, holding and tapping.
- Prepare and approve charge mixes for each grade, balancing chemistry, cost and available scrap, returns, pig iron and ferro-alloys.
- Control tapping temperature, pouring temperature and pouring time to reduce cold shuts, misruns and shrinkage.
- Ensure correct ladle practice: preheating, treatment, inoculation, slag removal and transfer.

Metallurgy and quality

- Achieve target chemistry for every heat using spectrometer results, carbon equivalent and thermal analysis; approve corrections before tapping.
- Run spheroidisation (magnesium treatment) and inoculation for SG/ductile iron, and nodularity and microstructure control with the lab.
- Investigate metallurgical defects (gas porosity, slag inclusions, shrinkage, hard spots, carbides, low nodularity) and drive root-cause and corrective actions.
- Maintain heat records, traceability and test-bar data for customer and certification audits (IATF 16949 / ISO 9001 where applicable).
- Work with Quality, Methods and the Sand Lab on scrap and rework reduction.

Cost, power and materials

- Own melting cost per tonne: power (kWh/t), metallic yield, alloy additions, refractory and consumables.
- Optimise furnace power usage against contract demand and time-of-day tariffs; minimise holding time and idle losses.
- Set specifications and grading for incoming scrap, pig iron, ferro-alloys and inoculants; work with Purchase and Stores on stock levels and supplier quality.
- Track and reduce melt loss,



spillage and slag metal; maximise return of runners and risers.

Equipment, refractory and maintenance

- Plan furnace relining, sintering and patching; monitor lining life and wear to prevent run-outs and breakouts.
- Coordinate preventive maintenance of furnaces, power packs, cooling systems, cranes, ladles and the spectrometer with the Maintenance team.
- Keep critical spares and refractory stock available; lead breakdown recovery to limit lost pouring time.

Health, safety and workplace

- Enforce safe work practice for molten metal, including PPE, moisture-free charge, ladle inspection, crane safety and emergency drills.
- Lead hazard identification, near-miss reporting and incident investigation in the melt shop.
- Ensure compliance with factory, pollution-control and environmental requirements: fume extraction, dust collection, slag and waste disposal.

People and leadership

- Lead, schedule and develop the melting team across all shifts; set clear targets and review performance.
- Train operators on standard operating procedures, furnace handling and safety; build multi-skilling and succession.
- Maintain discipline, attendance and a positive shop-floor culture.

Continuous improvement and reporting

- Drive improvement projects (Kaizen, 5S, TPM, Six Sigma) on yield, energy, rejection and productivity.
- Prepare daily and monthly melt-shop reports: production, power, yield, rejection, cost and downtime.
- Support new-grade and new-part development with Methods and Engineering, including trial heats and process validation.

Pay: ₹250,000.00 - ₹800,000.00 per year

Benefits:

- Commuter assistance
- Food provided
- Leave encashment
- Provident Fund

Location:

- Gummidipoondi, Chennai, Tamil Nadu (Required)

Work Location: In person

📌 Melting Manager Foundry (India)
🏢 Southern Alloy Foundries Private
📍 India