Melting Incharge

Job Title: GDC Manager Melting

Department: Foundry / Gravity Die Casting (GDC)

Location: Ahmednagar

Company: Indosculp Autocomp Pvt. Ltd.

Reporting To:

Job Purpose:

melting operations for the Gravity Die Casting (GDC) division

Key Responsibilities:

1. Melting & Production Management

• Plan, organize, and control daily melting operations as per production schedule.
• Maintain required melt quantity, temperature, and alloy composition.
• Ensure continuous and defect-free metal supply to GDC machines.
• Coordinate closely with the die casting, machine shop, and maintenance teams for smooth operations.
• Monitor furnace efficiency and minimize downtime.

2. Process & Quality Control

• Maintain alloy chemistry and temperature consistency throughout melting and pouring.
• Control impurities, hydrogen levels, and inclusion content through proper degassing and fluxing.
• Conduct regular spectro analysis and implement corrective actions for out-of-spec results.
• Analyze melt-related defects (porosity, blowholes, inclusions) and implement preventive measures.
• Ensure adherence to

  IATF 16949 / ISO 9001

  quality standards.

3. Equipment & Maintenance

• Supervise operation and upkeep of melting furnaces (crucible or reverberatory), ladles, and metal handling systems.
• Ensure timely

  preventive and predictive maintenance

  of melting and holding furnaces.
• Coordinate with maintenance for calibration of temperature sensors, thermocouples, and control systems.

4. Raw Material & Inventory Management

• Monitor and control usage of

  aluminium ingots, master alloys, fluxes, and consumables

  .
• Achieve optimum

  metal recovery and yield

  ; minimize dross and melt loss.
• Maintain proper documentation, traceability, and FIFO for all materials.

5. Safety, Environment & Compliance

• Enforce safety rules for handling molten metal, gas systems, and furnaces.
• Conduct safety training and ensure use of PPE by all melting personnel.
• Ensure compliance with

  ISO 14001 (Environment)

  and

  OHSAS 45001 (Safety)

  standards.

6. Team Leadership & Development

• Supervise and lead a team of shift in-charges, operators, and helpers.
• Allocate manpower effectively across shifts.
• Conduct regular skill upgradation and training programs.
• Maintain discipline, motivation, and team performance.

7. Continuous Improvement & Cost Control

• Implement

  Kaizen, 5S, Lean Manufacturing, TPM, and Energy Saving

  initiatives.
• Optimize energy and gas consumption in melting processes.
• Drive

  cost reduction projects

  related to metal recovery, flux consumption, and furnace efficiency.
• Monitor and report key performance indicators (KPIs) such as

  yield %, rejection %, OEE, and energy/unit metal melted

  .

Qualification:

• Diploma / B.E. / B.Tech. in Metallurgy, Mechanical, or Production Engineering.

Experience:

• 08-10 years

  of experience in

  Aluminium Gravity Die Casting (GDC) Foundry operations

  .
• Proven experience in

  melting and alloy control

  for

  automotive aluminium components

  such as outer tubes, shock absorber parts, and gearbox housings.
• Exposure to

  low pressure / gravity die casting

  preferred.

Skills & Competencies:

• Strong knowledge of

  Aluminium alloys and melt treatment processes

  .
• Expertise in

  Furnace operations, Degassing, Fluxing, and Spectro Analysis

  .
• Leadership, analytical thinking, and decision-making ability.
• Proficiency in

  process documentation, root cause analysis (8D/Why-Why)

  .
• Sound understanding of

  ISO / IATF / Safety systems