Role & responsibilities: Preferred High Pressure die casting Manufacturing unit Experience JD Key Responsibilities: Lead NPD projects for HPDC components from concept through industrialization. Drive project planning, budgeting, and execution. Lead customer interactions, technical reviews, and audits. Approve and monitor DFM, FMEA, APQP, and control plans. Oversee die/tooling design reviews, trials, and approvals. Ensure timely PPAP submission and SOP readiness. Manage and mentor NPD engineers and assistant managers. Drive continuous improvement, VA/VE initiatives, and cost optimization. Support business development in technical feasibility and costing. Ensure compliance with IATF 16949, ISO 9001, and customer-specific requirements. Skills & Competencies: Deep knowledge of HPDC processes, tooling, and defect resolution. Strong leadership and team management skills. Hands-on experience in APQP, PPAP, FMEA, SPC, and MSA. Excellent communication, customer handling, and project management skills. Exposure to CAD/CAM and simulation software (e.g., Magmasoft, ProCAST) preferred.
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 Skills MIS Communication Skill Time Management Problem Solving Skill