Manager: Aluminum Casting Expert

Position Overview:

The Aluminum Casting Expert will be responsible for overseeing the development and manufacturing of aluminum castings at our Supplier base used in Medium Voltage GIS applications. With more than 15 years of experience in the casting and foundry industry, the ideal candidate will have a deep understanding of aluminum casting techniques, quality control measures, and process optimization in an industrial setting. The role requires collaboration with RD, engineering, Quality and production teams to ensure that the castings meet the high standards required for GIS systems.

Key Responsibilities:

Casting Process Management: Lead the end-to-end process for aluminum casting used in Medium Voltage GIS systems, from design and material selection to production and final inspection at our supplier base.

Design and Development: Collaborate with engineering and RD teams to develop casting designs that meet the technical requirements of GIS applications, ensuring they meet safety, durability, and performance standards.

Process Optimization: Identify opportunities for process improvements in mold design, material usage, casting techniques, and overall manufacturing efficiency. Ensure continuous improvement in casting productivity, quality, and cost-effectiveness.

Quality Assurance: Implement and enforce stringent quality control measures throughout the casting process. Conduct regular inspections and testing to ensure that all castings meet the required standards, including dimensional accuracy, surface finish, and mechanical properties.

Troubleshooting and Problem Resolution: Analyze and resolve any casting defects or failures that occur during the production process. Use advanced problem-solving techniques to identify root causes and implement corrective actions.

Collaboration and Cross-Functional Work: Work closely with cross-functional teams, including Engineering, Quality, Production, and Supply Chain, to ensure alignment between casting processes and the overall production workflow.

Technology and Innovation: Stay current with industry trends, new casting technologies, and innovations in materials science. Integrate new casting techniques and materials that improve product quality, performance, and cost efficiency.

Mentorship and Training: Mentor and guide junior engineers and technicians in casting processes and quality standards concerning cast-friendly designs. Lead training sessions to ensure team members are equipped with the necessary skills and knowledge.

Documentation and Reporting: Maintain detailed records of casting specifications, process parameters, inspection results, and any corrective actions taken. Prepare technical reports and presentations for senior management as required and for the Aluminium Casting Experts Committee (ACEC) as required.

Key Qualifications:

Experience: Minimum of 15 8-10 years of experience in the aluminum casting or foundry industry, with significant exposure to industrial applications, preferably in the electrical or power sector.

Technical Expertise: Strong knowledge of aluminum alloys, casting methods (such as sand casting, die casting, or investment casting), mold design, and quality control processes. Familiarity with casting processes for electrical equipment is highly desirable.

Industry Knowledge: Experience in casting applications for Medium Voltage or High Voltage Gas Insulated Switchgear (GIS) or similar electrical infrastructure components will be an advantage.

Education: Bachelors degree in Mechanical Engineering, Metallurgy, Materials Science, or a related field. A Masters or doctoral degree is an additional advantage.

Process and Product Development: Hands-on experience in the development of new casting processes, along with a strong understanding of product lifecycle management and quality assurance practices and relevant standards.

Problem-Solving: Excellent analytical, troubleshooting, and problem-solving skills, with the ability to address complex casting issues and implement effective solutions.

Leadership: Ability to lead and mentor teams, manage projects, and work effectively in a cross-functional environment.

Communication: Strong verbal and written communication skills to interact with both technical and non-technical stakeholders.

Certifications (Preferred): Knowledge of ISO standards, candidate should be Certified auditor and have knowledge in relevant global standards used in Casting/Foundry industry.

Desired Skills:

Experience with advanced casting technologies such as mold production, rapid prototyping, or other innovative casting solutions.

Familiarity with CAD software (e.g., AutoCAD, SolidWorks, NX) for mold design and process simulation.

Understanding of environmental and sustainability considerations in the foundry industry.

Job requires extensive traveling to potential supplier base within India and Internationally.

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We are looking forward to receiving your online application. Please ensure you complete all areas of the application form, to the best of your ability to help us review your suitability for the role.