Assistant General Manager CCM

Department

Role Purpose

To lead, manage, and optimize the operations and maintenance of the Continuous Casting Machine (CCM) in a 0.75 MTPA Steel Melting Shop equipped with an Electric Arc Furnace (EAF), ensuring high productivity, safety, quality of billets/blooms/slabs, cost efficiency, and compliance with operational standards.

Key Responsibilities

1. Operations Management

• Ensure smooth and uninterrupted CCM operation to meet production targets.
  
• Monitor and control casting parameters (superheat, casting speed, tundish temperature, mold level control, secondary cooling, etc.).
  
• Coordinate with EAF & LF (Ladle Furnace) for heat sequence planning.
  
• Ensure proper sequence casting, yield improvement, and minimization of turnaround time.
  
• Drive initiatives for productivity improvement and energy optimization.
  

2. Quality Assurance

• Ensure billets/blooms/slabs meet dimensional, surface, and internal quality standards.
  
• Monitor mold oscillation, lubrication, water flow, and EMS (Electromagnetic Stirring, if available) to minimize surface and internal defects.
  
• Collaborate with Quality Department for metallurgical defect analysis and corrective action.
  
• Ensure strict adherence to customer specifications and ISO/quality standards.
  

3. Maintenance & Reliability

• Oversee preventive and predictive maintenance of CCM equipment (mold, segments, hydraulic systems, secondary cooling, withdrawal & straightening units, rollers, cutting machines).
  
• Ensure availability of critical spares and consumables (mold powder, SEN, dummy bar, refractories).
  
• Implement TPM practices to maximize machine availability and reduce breakdowns.
  

4. People Management

• Lead and mentor a team of shift in-charges, operators, and maintenance staff.
  
• Provide technical training on casting operations, safety, and troubleshooting.
  
• Foster teamwork, accountability, and skill enhancement of workforce.
  

5. Safety, Health & Environment (SHE)

• Ensure compliance with safety standards, SOPs, and statutory regulations.
  
• Enforce safe working practices during mold changes, tundish changes, dummy bar insertion, and emergency handling.
  
• Promote a culture of zero accidents and continuous improvement in SHE performance.
  

6. Cost & Resource Management

• Monitor and control consumption of refractory, fluxes, and utilities (power, water, oxygen, etc.).
  
• Optimize cycle time, yield, and energy consumption to reduce cost/ton of casting.
  
• Implement cost-saving projects and process improvements.
  

7. Coordination & Reporting

• Coordinate with SMS, Mechanical, Electrical, Instrumentation, and Quality teams for integrated operations.
  
• Prepare and analyze daily/weekly/monthly CCM performance reports (yield, downtime, quality defects, cost).
  
• Report key operational KPIs to SMS Head and Plant Management.
  

Key Performance Indicators (KPIs)

• Heat-to-cast ratio and sequence length achieved.
  
• CCM yield and productivity (tons/hour).
  
• Quality rejection rate (%).
  
• CCM downtime and breakdown hours.
  
• Safety incidents (LTI, MTI, near misses).
  
• Cost/ton of casting vs. budget.
  

Qualifications & Experience

• Education

  : B.Tech/B.E. in Metallurgy / Mechanical / Electrical Engineering.

• Experience

  : 15–20 years in Steel Industry with minimum 7–8 years in CCM operation of EAF-based SMS.
• Proven experience in billet/bloom/slab casting, mold management, and defect control.
  
• Exposure to advanced CCM technologies (EMS, soft reduction, automation) preferred.
  

Competencies & Skills