Job Description:

JOB DESCRIPTION (JD)

Position: Assistant Manager – Process Control (Casting)

Company: Munjal Kiriu Industries Pvt. Ltd.
Department: Foundry / Process Control
Location: Vithalapur / Mandal, Ahmedabad, Gujarat
Designation: Assistant Manager – Process Control
Reporting To: Manager / Senior Manager – Process Control / Foundry

1. Job Objective

To monitor, control and improve critical foundry process parameters across Melting, Sand Plant, Moulding, Pouring and Casting operations to ensure consistent product quality, minimum rejection, stable processes and achievement of production targets.

The role will be responsible for process parameter control, SPC, process capability, defect reduction, root-cause analysis and continuous improvement in ferrous casting operations.

2. Key Responsibilities

A. Process Control – Foundry

• Monitor and control critical process parameters across:
  • Melting
  • Sand Plant
  • Moulding / DISA
  • Core / Moulding process
  • Pouring
  • Shakeout and Shot Blasting
• Define and maintain process control parameters and operating windows.
• Ensure adherence to standard operating procedures, control plans and process sheets.
• Monitor process deviations and initiate immediate corrective actions.
• Ensure proper documentation and traceability of process parameters.

B. Melting Process Control

• Monitor critical melting parameters such as:
  • Chemical composition
  • Furnace temperature
  • Charging mix
  • Holding time
  • Inoculation
  • Nodulizing / treatment parameters, wherever applicable
• Coordinate with the Melt Shop team for maintaining consistent metallurgical quality.
• Analyze chemical and metallurgical test results and take corrective actions.
• Reduce casting defects related to improper chemistry, temperature and metallurgical parameters.

C. Sand Process Control

• Monitor green sand parameters including:
  • Moisture
  • Compactability
  • Permeability
  • Green compression strength
  • Sand temperature
  • AFS / grain-related parameters
  • Bentonite and additive levels
• Control sand plant parameters and maintain process stability.
• Analyze sand-related casting defects and implement corrective actions.
• Work closely with Sand Plant and Production teams for continuous improvement.

D. Moulding & Pouring Control

• Monitor DISA moulding parameters and identify process abnormalities.
• Ensure mould hardness, mould density, dimensional accuracy and other critical parameters are within defined limits.
• Monitor pouring temperature, pouring time and other critical pouring parameters.
• Ensure proper adherence to approved process windows.
• Investigate moulding and pouring-related casting defects.

E. Quality & Defect Reduction

• Analyze internal rejection and customer complaints related to casting process.
• Conduct Root Cause Analysis (RCA) using 5 Why, Fishbone, Pareto and other problem-solving techniques.
• Drive reduction of defects such as:
  • Blow holes
  • Sand inclusion
  • Shrinkage
  • Misrun / cold shut
  • Mismatch
  • Scab
  • Hard spot
  • Porosity
  • Slag inclusion
  • Dimensional defects
• Develop and implement corrective and preventive actions.
• Monitor rejection trends and prepare monthly improvement plans.

F. SPC & Process Capability

• Implement and monitor SPC for CTQ / critical process parameters.
• Prepare and maintain control charts.
• Conduct process capability studies such as Cp, Cpk, Pp and Ppk.
• Identify process variation and initiate improvement actions.
• Ensure real-time monitoring of critical parameters wherever applicable.
• Support digitalization of process monitoring and data collection.

G. Continuous Improvement

• Drive Kaizen, Poka-Yoke and process improvement initiatives.
• Identify opportunities for reduction in:
  • Rejection
  • Rework
  • Scrap
  • Energy consumption
  • Sand consumption
  • Process variation
• Work with Production, Quality, Maintenance and Tooling teams for improvement projects.
• Support new product development and process trials.

3. Documentation & Systems

• Prepare and maintain:
  • Process Control Plans
  • Process Parameter Sheets
  • SOP / Work Instructions
  • PFMEA inputs
  • SPC records
  • Process capability reports
  • Defect analysis reports
  • CAPA / 8D reports
• Ensure compliance with IATF 16949, ISO 9001 and customer-specific requirements.
• Maintain process traceability and records as per company requirements.

4. Team & Cross-Functional Coordination

• Coordinate with Foundry Production, Quality, Maintenance, Tool Room, R&D/NPD and Laboratory teams.
• Guide engineers, supervisors and operators on process-control requirements.
• Conduct training on process parameters, defect prevention and standard operating procedures.
• Participate in daily production and quality review meetings.

5. Key Performance Indicators (KPIs)

• Foundry rejection %
• Rework %
• Scrap %
• Customer complaints / PPM
• Process capability – Cpk
• Process parameter adherence
• Casting defect reduction
• Sand parameter stability
• Melting chemistry and temperature compliance
• Kaizen / cost-saving initiatives
• Customer complaint closure time

6. Educational Qualification

BE / B.Tech / Diploma – Mechanical / Metallurgy / Production / Foundry Technology

Metallurgy / Foundry Technology candidates will be preferred.

7. Experience

6–10 years of relevant experience in ferrous foundry / casting process control, preferably in an automotive OEM/Tier-1 manufacturing environment.

8. Preferred Industry / Technical Exposure

Candidates should preferably have experience in:

• Automotive casting / ferrous foundry
• DISA moulding line
• Induction melting furnace
• Green sand process
• Melting & pouring process
• Casting defect analysis
• SPC & Process Capability
• PFMEA / Control Plan
• 8D / RCA / CAPA
• Kaizen / Poka-Yoke
• IATF 16949
• Quality laboratory coordina