Sr. Engineer Melting

Roles & Responsibilities
Job Summary: We are seeking a skilled and experienced Foundry Senior Engineer – Melting & Pouring specializing in Air Melting and Pouring operations for Stainless Steel, Super Duplex, Inconel and higher alloys to join our high precision foundry team in Lucknow. As a Foundry Engineer – Melting and Pouring, you will be responsible for overseeing and optimizing the air melting and pouring processes in our facility, ensuring the production of high-quality castings for Industrial and Defence applications. You will work closely with cross-functional teams, including metallurgists, technicians, and production staff, to meet project requirements and achieve key performance indicators (KPIs). This is a critical role that requires an understanding of air melting processes and technical parameters, effective management of melting and pouring team, attention to detail, and a commitment to process improvement.
Key Responsibilities:
Plan, organize, supervise and execute melting and pouring operations to ensure the production of defect-free and high-quality castings.
Manage a high-performance team to ensure optimal outputs and on-time delivery while adhering to quality requirements and process controls.
Monitor and optimize the melting and alloying processes to achieve precise metal composition and desired mechanical properties.
Develop and implement standard operating procedures (SOPs) for melting, alloying, and pouring processes, ensuring adherence to safety, quality, and efficiency standards.
Conduct regular inspections and maintenance of melting equipment, furnaces, ladles, and other related tools to ensure their proper functioning and longevity.
Collaborate with metallurgists and quality control teams to perform material analysis, such as chemical composition and microstructural examinations, to ensure compliance with specifications and customer requirements.
Identify areas for process improvement and implement corrective actions to enhance productivity, reduce waste, and optimize resource utilization.
Train and mentor technicians and operators on proper melting and pouring techniques, safety protocols, and quality standards.
Maintain accurate records and documentation of production activities, including batch records, process parameters, and quality control data.
Stay up-to-date with industry advancements, emerging technologies, and best practices related to melting and pouring operations in the foundry sector.
Participate in continuous improvement initiatives and contribute to the development of new casting techniques and technologies.
The Key Performance Indicators (KPIs) for this role shall be:
Scrap and rework reduction: Minimize scrap and rework rates through process optimization and quality control measures.
On-time delivery: Ensure timely completion of melting and pouring operations to meet production schedules and customer commitments.
Yield improvement: Increase yield by optimizing metal utilization and reducing material waste during the melting and pouring processes.
Quality compliance: Achieve and maintain compliance with customer specifications and industry quality standards.
Cost optimization: Identify and implement cost-saving initiatives without compromising quality and safety standards.
Team performance: Foster a collaborative work environment, provide guidance to team members, and promote professional development.
Ideal Qualifications:
Bachelor's degree or Diploma in Metallurgical Engineering, Mechanical Engineering, Materials Science, or a related field.
Proven experience 4+ years) in foundry operations in a Stainless Steel Foundry is preferable, with a focus on air melting and pouring processes, preferably in high-precision foundries serving industrial and defence sectors.
In-depth knowledge of metallurgy, metal alloys, and their behavior during melting, alloying, and solidification processes.
Strong understanding of foundry equipment, such as induction furnaces, crucibles, ladles, and pouring systems.
Familiarity with quality control techniques and analysis methods used in the foundry industry.
Proficient in interpreting technical drawings, specifications, and manufacturing instructions.
Experience with process improvement methodologies, such as Six Sigma or Lean Manufacturing, is a plus.
Problem-solving skills and the ability to troubleshoot and resolve technical issues in a fast-paced environment.
Strong communication and interpersonal skills to collaborate effectively with Melting and Pouring Team and other production departments and external stakeholders.
Detail-oriented with a commitment to maintaining accurate records and documentation.
Knowledge of safety regulations and practices related to foundry operations.
Additional Responsibilities:
Quality Control:
Develop and implement quality control measures and procedures for the melting and pouring operations to ensure the production of defect-free castings.
Collaborate with the quality control team to establish quality standards, conduct inspections, and perform non-destructive testing to validate the integrity and quality of castings.
Analyze quality control data, identify trends, and implement corrective actions to address any deviations from the specified quality requirements.
Conduct root cause analysis and implement preventive measures to minimize the occurrence of quality issues in the manufacturing process.
Ensure compliance with relevant industry standards, such as ISO 9001 or specific customer quality certifications.
Furnace Management:
Oversee the operation and maintenance of melting furnaces, including induction furnaces, ensuring their optimal performance and longevity.
Develop and execute a preventive maintenance plan for furnaces, coordinating with maintenance technicians to schedule regular inspections, repairs, and calibration.
Monitor furnace parameters, such as temperature, pressure, and power consumption, to ensure consistent and efficient melting operations.
Implement energy-saving initiatives and optimization strategies to reduce furnace energy consumption while maintaining the required production output.
Collaborate with suppliers and equipment manufacturers to stay updated on the latest furnace technologies and recommend upgrades or replacements as needed.
Least Cost Mix:
Optimize the metal alloy mix and composition to achieve the desired mechanical properties while minimizing costs.
Analyze cost data and conduct cost-benefit analyses for different alloy compositions and material suppliers.
Collaborate with procurement and finance teams to source materials at competitive prices without compromising quality and performance.
Identify opportunities for scrap recycling and material reclamation to reduce waste and enhance cost-effectiveness.
Work closely with metallurgists and suppliers to explore alternative materials or alloying techniques that offer cost savings without sacrificing quality.
Desired Candidate Profile
Education and Certifications:
• Bachelor's degree or Diploma in Metallurgical Engineering, Mechanical Engineering, Materials Science, or a related field
Experience:
· Proven experience (typically 4+ years) in foundry operations, with a focus on air melting and pouring processes, preferably in high-precision stainless steel foundries.
Technical / Functional Expertise & other competencies:
In-depth knowledge of metallurgy, metal alloys, and their behavior during melting, alloying, and solidification processes.
Strong understanding of foundry equipment, such as induction furnaces, crucibles, ladles, and pouring systems.
Familiarity with quality control techniques and analysis methods used in the foundry industry.
Proficient in interpreting technical drawings, specifications, and manufacturing instructions.
Experience with process improvement methodologies, such as Six Sigma or Lean Manufacturing, is a plus.
Excellent problem-solving skills and the ability to troubleshoot and resolve technical issues in a fast-paced environment.
Strong communication and interpersonal skills to collaborate effectively with cross-functional teams and external stakeholders.
Detail-oriented with a commitment to maintaining accurate records and documentation.
Knowledge of safety regulations and practices related to foundry operations.

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