Job Description

JD – Foundry (BOM, Metal Control & Process Systems)

Responsible for preparation, validation, correction, and continuous improvement of Metal BOM Casting BOM and routing. Lead melting loss study, metal yield optimization, inventory accuracy, SOP implementation, routing validation, and digitization initiatives to improve cost control and process transparency in foundry operations.

Key Responsibilities

1. Melting Loss Study

• Conduct structured melting loss study -Metal grade group wise (Refer table no. 1)

• Periodic check of melting losses as per mentioned in the WI.

• Check input charge accuracy of BOM on periodic basis and correct accordingly if any more or less addition is required to get desired metal chemistry.

• Monitor melting losses (Furnace yield%) on monthly basis and provide root cause analysis whenever there is less outcome.

2. Metal loss study

• Conduct structured metal loss study for the components mentioned in table no.2

• Periodic check of metal losses as mentioned in the WI.

• Monitor metal losses on monthly basis and provide root cause analysis whenever there is less outcome on desired range.

• Take approval of plant head if metal losses for particular components are more than desired range.

• Initiate action plans along with method and operation to reduce the metal losses.

3. Casting BOM Accuracy & Validation

• Develop casting-wise BOM after receiving the required requisite like sand, binder, coatings, sleeves, casting weight, RR ,etc from the method and operations in charge.

• Compare system BOM vs actual consumption on monthly basis.

• Identify variance and implement corrective actions.

• Improve costing accuracy through precise control on yield and metal losses.

• undefined

  4. Inventory Physical Verification

  Ensure periodic physical inventory taking from stores as mentioned in WI/QN for runner and risers, alloys, consumables.

  Reconcile system stock vs physical stock.

  Control excess inventory and improve inventory turnover ratio.

  5. Routing Validation & Process Standardization

  Validate routing in SAP.

  Compare planned vs actual cycle time.

  Standardize routing for repeatable castings.

  6. SOP Implementation & Process Validation

  Ensure implementation of processes as mentioned in the SOP’s.

  Develop new SOP’s as per process requirements.

  Conduct periodic SOP compliance audits.

  Monitor deviation and corrective action closure.

  7. Digitization & System Improvements- Lead digitization initiatives in foundry.

  09. Data Analysis & Reporting

  Monthly MIS reporting:

  Metal loss% - Melt shop and shop floor.

  Alloy consumption variance

  Molding material -Consumable material consumption variance

  Condut root cause analysis for melting and metal loss variance, Yield drop, Inventory variance.

  SOP compliance %.

  undefined

  Skills :

  Knowledge of SAP

  Various foundry processes

  Soft skills

  Educational Qualification

  BE/BTech – Metallurgy / Mechanical

  8–15 years of experience in foundry operations