Manager /Sr manager - Melting - High Pressure Die Casting

Key Responsibilities:

1. Production & Process Management

• Plan, organize, and control melting shop operations to meet production requirements.
  
• Ensure consistent metal quality (temperature, chemistry, cleanliness) before transfer to die casting machines.
  
• Oversee charge preparation, alloying, fluxing, and degassing processes.
  
• Monitor melting furnaces (holding, tower, crucible, gas/electric) for optimum utilization.
  
• Implement lean manufacturing & process improvements to reduce wastage and cost.
  

2. Quality & Metallurgy

• Maintain proper alloy composition and ensure adherence to metallurgical standards.
  
• Coordinate with Quality/NPD team for defect analysis (porosity, inclusions, etc.) and corrective actions.
  
• Conduct trials for new alloys/materials and ensure compliance to customer requirements.
  

3. People Management

• Lead, train, and guide melting shop operators, supervisors, and support staff.
  
• Ensure workforce discipline, skill development, and safe working practices.
  
• Develop a culture of accountability, continuous improvement, and teamwork.
  

4. Safety & Compliance

• Ensure strict adherence to EHS (Environment, Health & Safety) guidelines.
  
• Implement SOPs for safe furnace operations, metal handling, and emergency preparedness.
  
• Monitor energy consumption and comply with statutory norms.
  

5. Maintenance & Resource Management

• Coordinate with Maintenance team for preventive/corrective maintenance of furnaces, ladles, pumps, and related equipment.
  
• Optimize consumption of fluxes, gases, and energy to achieve cost-effectiveness.
  
• Control inventory of raw materials, consumables, and refractory items.
  

Key Skills & Competencies:

• Strong knowledge of

  aluminum alloy melting & treatment

  for HPDC.
• Experience in operating

  gas/electric melting furnaces, holding furnaces, and transfer systems

  .
• Understanding of metallurgical properties, casting defects, and corrective actions.
  
• Leadership, team management, and decision-making skills.
  
• Hands-on experience in implementing

  5S, Kaizen, TPM, Lean practices

  .
• Familiarity with

  ISO/TS 16949, IATF 16949, and EHS standards

  .

Qualification & Experience:

• B.E. / B.Tech. in Metallurgy / Mechanical / Production Engineering

  (preferred).
• 1015 years of foundry experience, with at least

  5+ years in melting operations

  in HPDC (Aluminum).
• Experience in

  automotive / HPDC background

Principal Accountabilities:

• Melting Operations Management

• Supervise and control melting shop operations of furnace, metal preparation, and alloy mixing.
• Ensure timely availability of molten metal for die casting machines.
• Plan and schedule melting activities in alignment with production requirements.
• Monitor and maintain correct alloy composition, temperature, and cleanliness of molten metal.
• Ensure that the molten metal meets the required chemical and physical properties.

• Team & Resource Management

• Lead, train, and supervise the melting team (operators, furnace attendants, etc.).
• Allocate tasks to melting operators and ensure efficient manpower utilization.
• Provide technical guidance for troubleshooting melting-related issues.
• Lead and manage a team and achieve the department KRAs.
• Ensure employee retention by reducing attrition.

• Process Optimization & Cost Control

• Optimize energy consumption and raw material usage to reduce melting costs.
• Identify and implement process improvements to increase efficiency.
• Reduce metal losses like dross, Spills.
• Melting loss Reduction.
• Increase the Crucible life to reduce the cost.
• Implementation of Kaizen, Poke Yoke to improve the process and reduce the cost.

• Raw Material & Infrastructure Project Management

• Lead the Project related to plant like new part development supports like trolley, Bins and angers.
• Ensure the raw material received as per the bill quantity or debit to the supplier.
• Ensure timely repair and maintain the trolley and bins.
• Negotiate with the vendor for best price and release PO.

• Safety, MIS & Documentation

• Maintain daily melting logs, alloy usage records, and furnace performance reports and provide MIS as per Management requirement.
• ISO & IATF Audit documents preparation for melting department.
• Report on material consumption, scrap, and metal yield.
• Improve the safety and 5S culture in the plant.

Knowledge & Skills needed to deliver on the accountabilities: Skills could be functional / technical / behavioral)

Technical Skills

• Melting Process knowledge
• Knowledge of HPDC Defect
• Negotiation skills

Soft

• MIS
• Communication Skill
• Time Management
• Problem Solving Skill