Asst. Manager / Dy. Manager Refractory Steel Melting Shop

Role & responsibilities

Key Responsibilities:

1. Refractory Planning & Installation

• Plan and execute refractory relining, patching, gunning, fettling, and maintenance for all SMS units.
  
• Supervise refractory lining of EAF roofs, sidewalls, hearths, spouts, LF/VD ladles, and tundish sections.
  
• Ensure correct drying, baking, and preheating procedures before furnace startup.
  
• Implement best practices for brick, castable, and monolithic installation as per approved drawings and specifications.
  
• Coordinate with production and maintenance teams to align lining schedules for minimal downtime and maximum equipment utilization.
  

2. Refractory Performance Monitoring

• Record and analyze refractory consumption, campaign life, and performance data for each furnace and ladle.
  
• Monitor refractory wear patterns, tapping temperatures, and slag chemistry for optimizing refractory performance.
  
• Track tundish and working lining life to maintain consistent casting quality and operational efficiency.
  
• Conduct root cause analysis for premature refractory failures and suggest corrective or design improvements.
  
• Support initiatives for material selection and design enhancement for improved refractory life and cost reduction.
  

3. Material Management & Coordination

• Plan refractory material requirements based on production forecasts and consumption patterns.
  
• Inspect incoming refractory materials for quality, dimensions, and adherence to specifications before acceptance.
  
• Maintain updated inventory records and ensure optimum stock levels to prevent production delays.
  
• Coordinate with procurement and stores departments for timely material availability.
  
• Evaluate vendor performance and assist in refractory trials for new materials or suppliers.
  

4. Process & Quality Control

• Ensure high-quality refractory lining through inspections, dimensional checks, and compliance with installation standards.
  
• Monitor operating parameters like slag composition, steel temperature, and furnace conditions that impact refractory life.
  
• Collaborate with production and process control teams to maintain optimal slag basicity and thermal conditions.
  
• Prepare and maintain refractory life charts, material usage reports, and daily consumption summaries.
  

5. Maintenance & Continuous Improvement

• Implement preventive maintenance schedules for refractory equipment such as gunning machines, mixers, and vibrators.
  
• Participate in performance review meetings and refractory failure investigations.
  
• Contribute to cost reduction initiatives by optimizing refractory consumption per ton of steel.
  
• Support continuous improvement programs such as

  Kaizen, TPM, and Six Sigma

  related to refractory management.

6. Safety & Compliance

• Follow and enforce all safety standards during refractory installation and maintenance activities.
  
• Ensure proper use of PPE and adherence to safety protocols during hot work and high-temperature operations.
  
• Conduct Job Safety Analysis (JSA) for critical refractory maintenance tasks.
  
• Ensure proper waste disposal and compliance with environmental standards.
  
• Maintain 5S and housekeeping standards in refractory storage and work areas.
  

7. Coordination & Reporting

• Coordinate closely with Operations, Mechanical, Electrical, and Production Planning teams for smooth refractory maintenance and changeovers.
  
• Support audits, cost analyses, and vendor performance assessments.
  
• Prepare and present daily, weekly, and monthly refractory performance and consumption reports.
  
• Maintain detailed records of lining history, life tracking, and performance trends in SAP or other maintenance management systems.

Preferred candidate profile

Qualifications & Experience:

Education:

• Diploma / B.E. / B.Tech in Ceramic Engineering / Metallurgy / Mechanical Engineering
  

Experience:

• Engineer:

  36 years of experience in refractory maintenance in Steel Melting Shop or similar industrial setup (EAF/LF/VD/CCM exposure preferred).

• Sr. Engineer:

  6–10 years of experience in refractory planning, lining supervision, and performance monitoring in an integrated steel or foundry plant.

Industry Preference:

• Integrated Steel Plant / Ferro Alloy / Foundry / Heavy Engineering
  

Key Skills & Competencies:

• Strong knowledge of refractory materials, properties, and installation methods.
  
• Hands-on experience in refractory relining, gunning, inspection, and maintenance activities.
  
• Familiarity with EAF, LF, VD, and CCM refractory systems and operational practices.
  
• Analytical approach to refractory life optimization and failure analysis.
  
• Understanding of refractory–slag–metal interactions and process impact.
  
• Proficiency in SAP, MS Excel, and maintenance management systems.
  
• Excellent communication, coordination, and reporting skills.
  
• Commitment to safety, quality, cost optimization, and continuous improvement.