Engineer, Melting Operations

Job Summary: We are seeking a skilled and experienced Foundry Engineer – Melting & Poursing specializing in Air Melting and Pouring operations for Stainless Steel, Super Duplex, Iconel and higher alloys to join our high precision foundry team in Lucknow. As a Foundry Engineer – Melting and Pouring, you will be responsible for overseeing and optimizing the air melting and pouring processes in our facility, ensuring the production of high-quality castings for Industrial and Defence applications. You will work closely with cross-functional teams, including metallurgists, technicians, and production staff, to meet project requirements and achieve key performance indicators (KPIs). This is a critical role that requires an understanding of air melting processes and technical parameters, effective management of melting and pouring team, attention to detail, and a commitment to process improvement.

Key Responsibilities:

• Plan, organize, supervise and execute melting and pouring operations to ensure the production of defect-free and high-quality castings.
• Manage a high performance team for ensuring optimal outputs and on-time delivery while adhering to quality requirements and process controls.
• Monitor and optimize the melting and alloying processes to achieve precise metal composition and desired mechanical properties.
• Develop and implement standard operating procedures (SOPs) for melting, alloying, and pouring processes, ensuring adherence to safety, quality, and efficiency standards.
• Conduct regular inspections and maintenance of melting equipment, furnaces, ladles, and other related tools to ensure their proper functioning and longevity.
• Collaborate with metallurgists and quality control teams to perform material analysis, such as chemical composition and microstructural examinations, to ensure compliance with specifications and customer requirements.
• Identify areas for process improvement and implement corrective actions to enhance productivity, reduce waste, and optimize resource utilization.
• Train and mentor technicians and operators on proper melting and pouring techniques, safety protocols, and quality standards.
• Maintain accurate records and documentation of production activities, including batch records, process parameters, and quality control data.
• Stay up-to-date with industry advancements, emerging technologies, and best practices related to melting and pouring operations in the foundry sector.
• Participate in continuous improvement initiatives and contribute to the development of new casting techniques and technologies.

The Key Performance Indicators (KPIs) for this role shall be:

• Scrap and rework reduction: Minimize scrap and rework rates through process optimization and quality control measures.
• On-time delivery: Ensure timely completion of melting and pouring operations to meet production schedules and customer commitments.
• Yield improvement: Increase yield by optimizing metal utilization and reducing material waste during the melting and pouring processes.
• Quality compliance: Achieve and maintain compliance with customer specifications and industry quality standards.
• Cost optimization: Identify and implement cost-saving initiatives without compromising quality and safety standards.
• Team performance: Foster a collaborative work environment, provide guidance to team members, and promote professional development.

Ideal Qualifications:

• Bachelor's degree or Diploma in Metallurgical Engineering, Mechanical Engineering, Materials Science, or a related field.
• Proven experience (2-4 years) in foundry operations in a Stainless Steel Foundry is preferable, with a focus on air melting and pouring processes, preferably in high precision foundries serving industrial and defence sectors.
• In-depth knowledge of metallurgy, metal alloys, and their behavior during melting, alloying, and solidification processes.
• Strong understanding of foundry equipment, such as induction furnaces, crucibles, ladles, and pouring systems.
• Familiarity with quality control techniques and analysis methods used in the foundry industry.
• Proficient in interpreting technical drawings, specifications, and manufacturing instructions.
• Experience with process improvement methodologies, such as Six Sigma or Lean Manufacturing, is a plus.
• Problem-solving skills and the ability to troubleshoot and resolve technical issues in a fast-paced environment.
• Strong communication and interpersonal skills to collaborate effectively with Melting and Pouring Team and other production departments and external stakeholders.
• Detail-oriented with a commitment to maintaining accurate records and documentation.
• Knowledge of safety regulations and practices related to foundry operations.

Pay: ₹250,000.00 - ₹400,000.00 per year

Benefits:

• Health insurance
• Provident Fund

Work Location: In person