Method Engineer

BEHARI LAL ENGINEERING LIMITED Alloy & Steel Castings
JOB DESCRIPTION

1. Position Summary
   The Method Engineer is responsible for the complete methoding of steel and alloy steel castings produced on the
   no-bake (chemically bonded) sand system, covering casting weights from 500 kg to 25 MT. The role owns the
   technical design of gating, feeding and risering systems, pattern and core-box requirements, and yield optimisation
   for a product mix that includes valve and pump bodies, wear parts and general engineering castings. The engineer
   drives first-time-right development of new castings, reduces methoding-related rejections, and coordinates casting
   simulation (currently outsourced) with the objective of progressively building this capability in-house.
2. Key Responsibilities
   Methoding, Gating & Feeding Design
   Design gating, running and feeding (riser / chill / padding) systems for heavy steel and alloy castings (500 kg
   25 MT) using modulus and solidification principles.
   Determine number, size and location of risers, chills, insulating / exothermic sleeves and cover material to
   ensure directional solidification and sound castings.
   Optimise pouring parameters pouring temperature guidance, pouring time, sprue / ingate ratios in
   coordination with the melting and pouring teams.
   Pattern & Core-Box Development
   ¢ Prepare pattern and core-box layouts, defining shrinkage / contraction allowances, machining allowances,
   draft, core prints and parting arrangement for the no-bake process.
   ¢ Coordinate pattern manufacture with in-house and external pattern shops; review, trial and approve first-off
   patterns and core boxes.
   ¢ Maintain pattern equipment records, revisions and physical condition to ensure dimensional accuracy of
   moulds and cores.
   Casting Simulation & Yield Optimisation
   ¢ Prepare inputs and coordinate solidification / mould-filling simulation with the outsourced simulation partner;
   interpret results and iterate the method to eliminate shrinkage porosity, cold shuts and inclusions before
   pattern release.
   ¢ Support the phased development of in-house simulation capability defining requirements, validating results
   against shop-floor outcomes and building standard practice.
   ¢ Drive casting yield improvement and accurate estimation of casting, feeder and pattern weights for costing and
   enquiry response.
   No-Bake Process, Method Sheets & Standardisation
   Job Description Method Engineer (Casting Shop)
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BEHARI LAL ENGINEERING LIMITED Alloy & Steel Castings
¢ Specify mould and core parameters for the no-bake system box sizes, mould thickness, hardness, coating and
closing requirements.
¢ Prepare and maintain method sheets, methoding drawings and process route cards, and standardise proven
methods across similar part families.
Rejection Analysis & Continuous Improvement
¢ Analyse casting defects (shrinkage, sand / slag inclusion, blowholes, cracks, mis-run, dimensional) and lead
root-cause analysis and corrective / preventive actions for methoding-related rejections.
¢ Track methoding KPIs and drive measurable reduction in rejection and rework.
New Product Development & Coordination
¢ Lead new casting development from customer drawing to approved first article, including feasibility,
methoding, sampling and validation.
¢ Interface with pattern shop, moulding, melting, fettling and quality functions, and provide technical support to
customers on castability, methoding and design-for-manufacture queries.
¢ Ensure methoding complies with applicable material and casting standards (e.g. ASTM, IS, EN) and internal
quality requirements.
3. Qualifications & Experience
¢ Education: Diploma / B.E. / B.Tech in Metallurgy, Mechanical or Foundry Technology (NIFFT or equivalent
preferred).
¢ Experience: Minimum 5 years of methoding / process engineering experience in a steel or alloy steel foundry,
preferably on the no-bake sand system and with heavy castings.
¢ Domain: Demonstrated hands-on methoding of medium-to-heavy castings; experience up to the 25 MT range
is a strong advantage.
4. Technical Skills & Competencies
¢ Simulation: Working knowledge of casting simulation software (e.g. MAGMASOFT, ProCAST, AutoCAST or
SOLIDCast) essential.
¢ CAD: Proficiency in CAD tools (e.g. AutoCAD, SolidWorks or Creo) for methoding layouts and pattern drawings
essential.
¢ Methoding: Strong command of methoding fundamentals gating and risering design, modulus method,
feeding distance, Chvorinovs rule and directional solidification.
¢ Process: Sound understanding of the no-bake (furan / alkaline-phenolic) sand system and its influence on
casting quality.
¢ Materials: Familiarity with carbon, alloy and stainless steel grades and relevant casting standards (ASTM / IS /
EN).
5. Desirable Attributes
¢ Exposure to valve / pump body and wear-part castings.
¢ Experience setting up or bringing simulation in-house.
¢ Knowledge of casting cost estimation and yield benchmarking.
6. Behavioural Competencies
¢ Analytical and structured problem-solving with a data-driven approach to defect reduction.
¢ Strong cross-functional coordination and clear technical communication.
¢ Ownership, accountability and a continuous-improvement mindset.
7. Key Performance Indicators
¢ Casting yield improvement (%) across the assigned part mix.
Job Description Method Engineer (Casting Shop)
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BEHARI LAL ENGINEERING LIMITED Alloy & Steel Castings
¢ Reduction in methoding-related rejection and rework (%).
¢ Methoding turnaround time for new enquiries and developments.
¢ First-time-right rate on new casting developments.
¢ Pattern / method development lead time.
This job description outlines the primary duties of the role and is not exhaustive; responsibilities may evolve with organisational needs.
Job Description Method Engineer (Casting Shop)
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