JOB PURPOSE:

• Set up and improve product quality characteristics, develop and provide safe operating practices and define measurement techniques to ensure that casting operations is able to produce value added products at the required quality, meeting customer’s specification.

• Set up and improve product quality characteristics, establish cross-departmental procedures (e.g., for bus bar, mill scrap), oversee recycled metal evaluation, and expand metallurgical services to support operational demands and increased customer-driven technical requirements.

• Contribute toward developing various alloys, products and processes to enhance the productivity while maintaining the lowest possible manufacturing costs without compromising the best quality target.

2.            KEY ACCOUNTABILITIES:

Safety:

• Ensure that subordinates are trained and developed to carry out their required duties in a competent manner and ensure that people working in his team follows safety rules and practices.

Quality:

• Direct the activities of a multi- cultured workforce efficiently and effectively to ensure Cast house produces a range of products and alloys to meet customer expectations.

• Initiates or participates in process/product optimisation drives to contribute toward continuous improvement in product quality and process efficiency

• Ensures that established product quality criteria related to metal cleanliness assessments of liquid metal, metallography studies of cast products are effectively utilized

• Establishes and validates TDS (Technical Data Sheets) across departments including Potroom Services (e.g., SRSS rotors), Reduction (e.g., TiB₂ granules), and external recycled scrap evaluation.

• Oversees full metallographic analysis of recycled/secondary aluminium products and implementation of scrap-based process protocols in coordination with cast house operations.

• Ensures procedures are developed for handling non-casthouse scrap sources (e.g., dig out, mill scrap, bus bars) to maintain quality consistency.

• Leads metal cleanliness monitoring plans aligned with client requirements and process capability reporting.

• Approves or rejects all consumables only after full metallurgical evaluation.

• Manages technical interface with growing customer base through audits, visits, and resolution of customer complaints.

• Ensure that the necessary practices and procedures, in place and applied in the Casthouse, are in compliance with ISO9001, ISO14001, IATF 16949 ,ISO 45001, VDA 6.3 & 6.5

• Develops and enforces metallurgical quality sessions for all shifts and levels to maintain high awareness across the workforce.

Budgets/Costs:

• Select /recommend metallurgical equipment to provide the necessary services required for technical development in the casting process to meet the technological as well as market requirements.

• Controls budgets and seeks to minimize costs where appropriate

• Explore potential for savings in controllable cost to achieve management actions without impacting the final product quality

Operations:

• Control the activities of metallographic & metal cleanliness assessment & develop necessary procedures to provide complete metallographic services for metal quality assessments, process control and customer’s complaints investigation.

• Establishes cross-functional task forces to investigate recurring operational issues and implement systemic solutions across departments.

• Assist, implement and maintain a systematic evaluation of the alloying materials to continuously improve product quality and process efficiency.

• Assist area senior manager in developing specification for refractory materials and other process materials & ensure that these materials are systematically evaluated and MSDS (Material safety Data sheet) are checked to avoid adverse effects on processes and products.

• Coordinates technical support to internal departments (ATA, Potroom, Power, Technology) to align with evolving product and scrap integration demands.

• Manages audits of consumables suppliers and integrates assessments into procurement qualification processes.

• Leads metallurgy team’s readiness and procedure setup for the recycling plant process/products including sampling and evaluation framework.

• Assist Area Director in the investigation of customer complaints/queries and technical support for both EGA and non-EGA metal.

• Participate in process/product optimisation drive to contribute in continuous improvement in product quality and process efficiency.

• Conducts internal and external quality audits to ensure that all processes and products are well aligned with ISO 19001 and IATF19469 requirements.

• Review & check the metallurgical equipment’s operating practices and calibrations validity to ensure that equipment’s calibrations are up to date, equipment’s are operated according to operating practices to sustain ISO/IEC 17025 latest revision accreditation.

• Manage R&D projects to run in-house or with external institutions while exploring new ideas and techniques to make sure that EGA always possess competitive edge in market to provide high quality products to its customers.

• Ensure that customer’s technical visits, process and product audits are effectively facilitated.

• Establish APQP, PPAP, FMEA and control plans/documents as per IATF16949 automotive standard and ensure a systematic approach for the validation & revalidation, root cause & failure analysis and corrective & preventive measures for all processes, products and customer complaints to fulfil IATF16949 automotive requirements.

• Ensure Lean principles are followed at all times to reduce waste and improve productivity 

• Attend various seminars and conferences with suppliers, users and customers. Provide technical supports/assistances in guidance of Director- metallurgy Services.

• Monitor the training & development of all metallurgical staff to maintain high standards of operational performance and improve technical competence

• Oversees supplier development programs, working closely with vendors to improve quality, reliability, and innovation in alloying and consumable materials.

• Designs and monitors competency assessment programs for metallurgical staff to ensure continuous professional development and training compliance.

Desired Candidate Profile

•    Authority/ Decision making:

  
  

  • Liaise with the management regarding any threat to the process, quality of the products or significant threat to safety or environment.

  • Prepare an action plan and recommend the casting/ homogenisation practices for the new alloys & products.

  • Based on the Metallurgical knowledge and evaluation results decision is made on releasing /holding/reject the products

  • Assist Area  Director in the investigation of customer complaints and root cause analysis.

  • Authorizes casting practices and alloy developments tailored for highly sensitive alloys and large profiles to meet stringent customer requirements.

  • Leads evaluation and integration of consumables and process materials before implementation, ensuring compliance with EGA quality standards.

  • Guides responses to a significantly increased number of technical queries due to Technical Marketing involvement and customer expansion.

  • Understanding /implementing the requirements of ISO/IEC17025 as per latest revision implemented in Metallurgy laboratory

  • Explain, interpret, evaluate and recommend on Metal Cleanliness & Metallurgical Results (Test Results) and share it with metallurgy/operation team

  • Development, Modification, Verification and Validation of Test Methods

  • Oversees approval of documentation (procedures) related to metallurgical practices, ensuring alignment with internal standards and external requirements.

  • Leads decision-making on escalation of metallurgical issues to senior leadership, ensuring timely and effective resolution.

QUALIFICATIONS & SKILLS:

 Qualification:

• University Degree in Metallurgical /Chemical/Material Science Engineering or equivalent

Experience:

• Minimum of Five (5) years of experience in the Metallurgy and Six (6) years in smelting process/ casting operation, preferably in an Aluminium smelting industry in Metallurgy/process control area. A good understanding / working knowledge of the smelting process/casting operations

Skills:

• Overall knowledge and experience in the Metallurgy laboratory, Metallography, casting operations and process control.

• Knowledgeable in SPC methodology/ MSA /uncertainty measurement systems analysis, EDX, SEM analysis & mechanical (destructive & non-distractive) testing.

• Strategic cross-functional communication with internal stakeholders and customers/suppliers; technical depth in metallurgical evaluation, testing standards, and quality system alignment with ISO/IATF

• Excellent communication, strong leadership,  teamwork and  problem-solving skills.