Melting Incharge
4 days ago
Job Title: GDC Manager Melting
Department: Foundry / Gravity Die Casting (GDC)
Location: Ahmednagar
Company: Indosculp Autocomp Pvt. Ltd.
Reporting To: CEO
Job Purpose:
To lead and manage all melting operations for the Gravity Die Casting (GDC) division, ensuring consistent metal quality, process control, productivity, and safety. The role demands a deep understanding of aluminium metallurgy, furnace operation, and process optimization for automotive components like outer tubes, shock absorber parts, and gearbox housings.
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 Environment) and OHSAS 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
