Manager Foundry Production (Green Sand)

Role & responsibilities

• Daily Operations
• Plan and execute daily/weekly production as per PPC to achieve tonnage and delivery targets (OTIF).
• Manage molding (DISA/ARPA/manual), core availability, melting and nodularization (for SG iron), pouring discipline, shakeout, fettling/shot-blasting, and internal inspection.
• Ensure correct charge mix, tapping temperature, inoculation/spheroidization, and metallurgical properties (CE, C%, Si%, Mg recovery, nodularity, nodule count).
• Maintain sand system health: moisture, compactability, GCS, AFS fineness, permeability, LOI; coordinate with sand plant for stable parameters and low sand consumption/ton.
• Quality & Compliance
• Achieve internal and customer PPM targets; drive root cause analysis (8D, Ishikawa, Why-Why) and corrective actions.
• Maintain IATF 16949/ISO 9001 documentation: Process Flow, PFMEA, Control Plan, SOPs, WI, MSA, SPC; support APQP/PPAP and customer audits.
• Cost & Efficiency
• Control yield, metal loss, rework/re-melt, energy (kWh/ton), consumables (sand/bentonite/coal dust/inoculant/Mg alloy), and consumable life.
• Improve OEE for molding lines and critical equipment; implement SMED/Kaizen/TPM.
• People Leadership
• Lead and develop supervisors and shop-floor teams; plan manpower and training (safety, SOPs, skill matrices); enforce discipline and 5S.
• Maintenance Interface
• Coordinate with Maintenance for PM/CBM, breakdown reduction, and spares planning; support shutdowns and quick restorations.
• Safety, Health & Environment

• Enforce LOTO, PPE, molten metal handling, furnace and ladle safety; comply with statutory norms and internal EHS systems (incl. fire hydrants/manual alarms).
• Drive incident reporting, near-miss elimination, and housekeeping (5S).
• New Capacity & NPI
• Support installation/ramp-up of new molding lines and new products: trial planning, parameter setting, capability studies, and handover to serial production.
• Cross-Functional Collaboration
• Work with PPC, QA, Maintenance, Purchase, and Logistics to ensure material availability, smooth flow, and on-time dispatches.

• Preferred candidate profile

• Charge mix design, temperature control, inoculation/spheroidization practices, Mg treatment control, chill control, and microstructure targets (nodularity, pearlite/ferrite balance).
• Sand plant management (moisture/compactability loops, bentonite/coal dust addition control, return/new sand ratios, dust extraction).
• Defect prevention & analysis: sand inclusions, blowholes, shrinkage/porosity, misrun/cold shut, veining, scab, penetration, etc.
• Data-driven operations: SPC on sand and metal, pareto of defects, heat-wise traceability, and QRQC.

Behavioral Competencies

• Strong leadership and shop-floor presence; ability to coach and enforce standards.
• Bias for action, structured problem solving, and cross-functional collaboration.
• Discipline in documentation and audit readiness; commitment to safety.