Sr. Engineer Melting - Lucknow, India - PTC Industries Limited

Description

Roles & Responsibilities

Job Summary: We are seeking a skilled and experienced Foundry Senior Engineer – Melting & Pouring specializing in Air Melting and Pouring operations for Stainless Steel, Super Duplex, Inconel 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 to ensure 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 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.

Additional Responsibilities:

Quality Control:

• Develop and implement quality control measures and procedures for the melting and pouring operations to ensure the production of defect-free castings.
• Collaborate with the quality control team to establish quality standards, conduct inspections, and perform non-destructive testing to validate the integrity and quality of castings.
• Analyze quality control data, identify trends, and implement corrective actions to address any deviations from the specified quality requirements.
• Conduct root cause analysis and implement preventive measures to minimize the occurrence of quality issues in the manufacturing process.
• Ensure compliance with relevant industry standards, such as ISO 9001 or specific customer quality certifications.

Furnace Management:

• Oversee the operation and maintenance of melting furnaces, including induction furnaces, ensuring their optimal performance and longevity.
• Develop and execute a preventive maintenance plan for furnaces, coordinating with maintenance technicians to schedule regular inspections, repairs, and calibration.
• Monitor furnace parameters, such as temperature, pressure, and power consumption, to ensure consistent and efficient melting operations.
• Implement energy-saving initiatives and optimization strategies to reduce furnace energy consumption while maintaining the required production output.
• Collaborate with suppliers and equipment manufacturers to stay updated on the latest furnace technologies and recommend upgrades or replacements as needed.

Least Cost Mix:

• Optimize the metal alloy mix and composition to achieve the desired mechanical properties while minimizing costs.
• Analyze cost data and conduct cost-benefit analyses for different alloy compositions and material suppliers.
• Collaborate with procurement and finance teams to source materials at competitive prices without compromising quality and performance.
• Identify opportunities for scrap recycling and material reclamation to reduce waste and enhance cost-effectiveness.
• Work closely with metallurgists and suppliers to explore alternative materials or alloying techniques that offer cost savings without sacrificing quality.

Desired Candidate Profile

Education and Certifications:

• Bachelor's degree or Diploma in Metallurgical Engineering, Mechanical Engineering, Materials Science, or a related field

Experience:

· Proven experience (typically 4+ years) in foundry operations, with a focus on air melting and pouring processes, preferably in high-precision stainless steel foundries.

Technical / Functional Expertise & other competencies:

• 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.
• Excellent 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 cross-functional teams and external stakeholders.
• Detail-oriented with a commitment to maintaining accurate records and documentation.
• Knowledge of safety regulations and practices related to foundry operations.