Hiring for Head Foundry Project

Job Description:

Jpb Title          : Head Foundry Project

Location          : Belgaum
Department     : Projects / Foundry
Reports To      : CEO / COO / Managing Director
Experience      : 22+ years in heavy foundry operations, with min 5 years in project leadership
Industry          : Heavy Engineering / Automotive / Engine Casting / Foundry

• Job Summary

We are seeking a seasoned professional to lead the end-to-end execution of a greenfield or brownfield sand casting foundry project specializing in production of  large Engine Head & blocks using the No-Bake process. This role demands deep expertise in heavy ferrous casting, hands-on project management, and the ability to integrate process, people, and equipment into a high-performance, production-ready foundry.

• Key Responsibilities

1. Project Leadership

• Lead the complete lifecycle of the foundry project: design, planning, procurement, execution, commissioning, and handover.
• Develop and monitor detailed project timelines, milestones, budgets, and risk management plans.
• Ensure the project meets safety, quality, capacity, and performance targets.

2. Technical Design & Process Development

• Define technical specifications for the No-Bake sand casting process for 6-ton engine blocks.
• Work with design and tooling teams to ensure appropriate gating/riser systems, pattern equipment, and core box designs.
• Finalize equipment sizing and layout for molding lines, core shops, melting units, shakeout systems, and reclamation plants.
• Ensure integration of molding, melting, pouring, cooling, fettling, and finishing areas.

3. Equipment Selection & Commissioning

• Evaluate, select, and install foundry equipment:
• Induction furnaces (medium frequency, suitable for large melt volumes)
• No-Bake sand mixers and reclamation systems
• Core shooters and drying ovens
• Heavy-duty cranes and handling systems
• Pouring ladles, preheat stations, and temperature control systems
• Lead FAT, SAT, and performance trials for all major equipment.

4. Vendor & Contractor Management

• Identify and manage relationships with OEMs, consultants, EPC contractors, civil and MEP vendors.
• Ensure alignment of all external partners with project KPIs, cost controls, and timelines.
• Oversee vendor evaluation, techno-commercial negotiations, and contract execution.

5. Cross-Functional & Regulatory Coordination

• Collaborate with internal teams: Design, Manufacturing, Maintenance, EHS, HR, and Finance.
• Ensure compliance with local environmental, pollution control, and labor regulations.
• Obtain necessary statutory approvals (e.g., factory license, power, emissions, fire NOC, etc.).

6. Budget & Cost Management

• Prepare and manage the capital budget for the foundry project.
• Monitor and report project expenditures, and implement cost-control measures.

7. Team Development & Handover

• Build and lead a capable foundry project team (project engineers, supervisors, QA/QC, etc.).
• Train the operations team during trial and commissioning phases.
• Ensure a seamless handover to Foundry Operations post-commissioning.

• Required Qualifications & Skills

Education

• B.E. / B.Tech in Metallurgy / Mechanical / Foundry Technology
• Additional certifications in Project Management (PMP, PRINCE2) are a plus

Experience

• 22+ years in heavy sand casting foundry operations and project management
• Hands-on experience with No-Bake molding and large ferrous castings (5+ tons)
• Proven track record of leading or heavily contributing to a foundry setup project
• Strong knowledge of metallurgy, casting defects, and quality control systems (UT, RT, etc.)

Key Skills

• Foundry equipment sizing and layout design
• No-Bake sand systems, reclamation, and large mold handling
• Project planning, cost estimation, and resource management
• Leadership and stakeholder management
• EHS and regulatory compliance

• Desirable Attributes

• Experience with cylinder head or engine block casting is a strong advantage
• Familiarity with digital foundry technologies (Industry 4.0, SCADA, data logging)
• Understanding of lean manufacturing principles in foundry operations