Senior Manager / Manager Refractory (Steel Melting Shop)

Role & responsibilities

Key Responsibilities

1. Refractory Planning & Management

• Prepare and implement annual and monthly refractory maintenance plans for all SMS units.
• Schedule relining, patching, fettling, and gunning operations in coordination with production and maintenance teams.
• Ensure optimum utilization of monolithic, shaped, and unshaped refractories.
• Track and analyze refractory life, wear rate, and consumption across all SMS areas.
• Identify causes for premature refractory wear or failure and initiate corrective/preventive actions.
• Optimize slag composition, metal temperature, and operating parameters to enhance refractory performance.
• Benchmark refractory KPIs such as life, cost per ton, and specific consumption against industry standards.
• Lead trials and evaluate new refractory materials and vendors.

2. Performance Monitoring & Optimization

• Review refractory consumption data regularly and prepare cost and performance reports.
• Implement best practices and standard operating procedures (SOPs) for refractory installation, drying, and maintenance.
• Monitor drying and preheating cycles for ladles and tundishes.
• Maintain furnace lining charts, ladle life records, and tundish refractory history sheets.
• Conduct root cause analysis (RCA) for refractory failures and drive improvements.

3. Material Procurement & Vendor Coordination

• Prepare monthly refractory demand forecasts based on production schedules.
• Coordinate with procurement and stores to ensure timely availability of refractory materials.
• Conduct vendor evaluation, technical audits, and performance reviews.
• Ensure quality inspection of refractory materials at receipt and during installation.

4. Installation, Maintenance & Supervision

• Supervise refractory lining, gunning, and fettling activities in EAF, LF, VD, CCM, ladles, and tundishes.
• Ensure adherence to design drawings, refractories layout, and SOPs during installation.
• Coordinate with mechanical, production, and safety teams during shutdowns.
• Implement refractory consumption cost control programs ensuring optimal expenditure per ton of liquid steel.
• Monitor inventory levels to avoid shortages or overstocking.

5. Safety & Compliance

• Ensure safe working practices during refractory installation, handling, and hot repair jobs.
• Conduct safety audits, toolbox talks, and hazard identification (HAZOP) for refractory operations.
• Enforce compliance with company safety policies and environmental regulations.
• Maintain housekeeping and 5S standards in refractory storage and work areas.

6. Documentation & Reporting

• Maintain comprehensive refractory life, consumption, and performance records for all SMS units.
• Prepare and submit daily, weekly, and monthly performance and consumption reports.
• Support audits, ISO documentation, and technical reviews.
• Maintain detailed refractory consumption and life cycle analysis data.

7. Team Leadership & Development

• Lead a team of engineers, supervisors, and contractors to ensure effective refractory operations.
• Allocate work responsibilities, monitor progress, and ensure safety compliance.
• Conduct training and skill development programs for refractory team members.
• Promote teamwork, accountability, and continuous improvement culture.

Preferred candidate profile

Qualifications & Experience

• B.E./B.Tech in Ceramic, Metallurgical, Mechanical, or related Engineering discipline.

• Manager: 10 to 14 years of experience in refractory management at Steel Melting Shop or integrated steel plants.
• Senior Manager: 14 to 18 years of experience with proven expertise in refractory performance optimization across EAF, LF, VD, CCM operations.
• Industry experience in Integrated Steel Plant, Alloy Steel, or Ferro Alloy sectors preferred.