AGM/DGM Continuous Casting Machine (CCM) Operation

Role & responsibilities

Key Responsibilities

• Lead and manage all CCM operations, ensuring continuous, safe, and defect-free casting of billets and blooms.
• Plan and execute casting schedules in coordination with EAF, LRF, VD, and Rolling Mill units to ensure heat arrival synchronization and sequence continuity, minimizing delays and metal loss.
• Develop and implement production plans targeting monthly and annual tonnage goals.
• Optimize mold level control, secondary cooling, withdrawal speed, and oscillation to enhance surface and internal quality.
• Review casting data and defect reports; implement corrective actions and collaborate with Quality Control and R&D teams on process improvements.
• Standardize and enforce operating procedures (SOPs) for casting, tundish preparation, and sequence management.
• Ensure high mechanical and electrical reliability of CCM machines, including molds, tundish cars, torch cutting, hydraulic systems, and secondary cooling equipment.
• Plan and monitor preventive, predictive, and breakdown maintenance activities with Mechanical, Electrical, and Instrumentation departments.
• Approve maintenance schedules, equipment overhauls, and major repairs; review downtime and feedback reports.
• Manage inventory and availability of critical spares and consumables such as molds, SENs, tundish refractories, and rollers.
• Enforce strict compliance with safety protocols, PPE usage, and SMS safety standards.
• Lead safety audits, risk assessments, and incident investigations within the CCM area.
• Ensure compliance with environmental regulations related to fume extraction, water discharge, and dust suppression.
• Promote 5S, housekeeping, and continuous safety training.
• Monitor KPIs including yield, productivity, sequence length, downtime, and lead improvement activities.
• Conduct daily and monthly performance reviews with operations and maintenance teams.
• Analyze trends and prepare MIS reports for senior management presentations.
• Identify opportunities for automation, digitization, and technological upgrades.
• Collaborate with OEMs such as Danieli, SMS, Primetals for performance improvements and technical modifications.
• Lead root cause analysis for major casting failures, breakouts, and nozzle blockages.
• Initiate and implement Kaizen, Six Sigma, and cost optimization projects.
• Lead, mentor, and develop a team of managers, engineers, and operators.
• Manage shift operations, manpower utilization, and skill matrix implementation.
• Conduct training on casting technology, safety, and problem-solving techniques.
• Foster a culture of accountability, teamwork, and innovation.

Preferred candidate profile

Qualifications & Experience

• B.E./B.Tech in Metallurgical, Mechanical, Production Engineering or related field.
• AGM: 16 to 20 years of integrated steel plant experience in CCM operations.
• DGM: 20 to 25 years of experience with leadership and technical expertise in billet/bloom casting operations.