AM /Deputy Manager Continuous Casting Machine (CCM) Operation

Role & responsibilities

Key Responsibilities

1. Casting Operations Management

• Supervise and control CCM operations during all shifts to ensure smooth, continuous, and defect-free casting.
• Coordinate with LRF and VD for timely ladle arrival, ensuring steel temperature and chemistry readiness.
• Manage tundish preparation, preheating, and sequence casting operations.
• Monitor and control mold level, withdrawal speed, and secondary cooling parameters to optimize billet/bloom quality.
• Ensure effective ladle changeovers and sequence management to minimize downtime and metal loss.
• Maintain accurate heat-wise and strand-wise records of production and operational parameters.

2. Product Quality and Process Control

• Ensure billets/blooms meet size, shape, surface quality, and internal soundness specifications.
• Monitor mold oscillation, lubrication, and water flow to prevent breakouts or surface defects.
• Work closely with Quality Control teams for product testing, inspection, and feedback.
• Analyze casting abnormalities such as stickers, breakouts, or segregation; implement corrective actions.
• Optimize operational parameters to improve casting yield, sequence length, and metallurgical quality.
• Implement and update Standard Operating Procedures (SOPs) for casting activities.

3. Equipment Maintenance Coordination

• Ensure proper functioning of molds, tundish cars, withdrawal and straightening units, torch cutting machines, and run-out tables.
• Coordinate with Mechanical, Electrical, and Instrumentation teams for preventive and corrective maintenance.
• Monitor tundish refractory lining condition, mold health, and spray nozzle performance.
• Support maintenance shutdown planning and provide feedback on equipment reliability.
• Ensure availability of consumables and critical spares like molds, SENs, nozzles, dummy bars, and rollers.

4. Safety and Environmental Compliance

• Implement stringent safety protocols and personal protective equipment (PPE) use during all CCM and ladle handling operations.
• Conduct safety checks, toolbox talks, and risk assessments specifically for CCM area activities.
• Manage fume extraction, water discharge, and scrap handling to comply with environmental norms.
• Promote and enforce 5S and housekeeping standards within the CCM area.
• Investigate safety incidents and implement preventive measures.

5. Process Optimization and Continuous Improvement

• Analyze casting data to improve productivity, reduce rejections, and enhance quality.
• Participate in root cause analysis for casting interruptions, nozzle blockages, and breakouts.
• Drive continuous improvement initiatives utilizing TPM, Kaizen, and Six Sigma methodologies.
• Work on yield improvement, energy reduction, and consumable cost optimization projects.
• Implement automation and digitization initiatives for improved process control.

6. Coordination and Reporting

• Coordinate closely with upstream EAF, LRF, VD, and downstream Rolling Mill teams for heat synchronization and sequence planning.
• Liaise with refractory, mechanical, and utility teams to ensure smooth CCM operation.
• Prepare and maintain shift reports, production summaries, and delay analyses.
• Present daily, weekly, and monthly performance reports and improvement plans to management.
• Support internal and external audits, inspections, and management reviews.

7. Team Management and Development

• Lead and supervise a team of engineers, operators, and technicians in the CCM area.
• Plan manpower deployment for casting sequences and shifts.
• Conduct training sessions on casting operations, tundish and mold management, and safety procedures.
• Evaluate team performance and foster a culture of responsibility, safety, and continuous learning.

Preferred candidate profile

Qualifications & Experience

• B.E./B.Tech in Metallurgical, Mechanical, Production Engineering, or related field.

• Assistant Manager: 6 to 10 years of experience in CCM operations in integrated steel plants.
• Deputy Manager: 10 to 14 years of experience in billet/bloom casting operations, with leadership exposure.
• Familiarity with integrated steel plant operations involving billet casting units is preferred.