Casting Engineer

JOB DUTIES AND RESPONSIBILITIES

1. Foundry Process Management: Plan, monitor, and optimize all Brass Foundry operations, including Core Making, Melting, Gravity Die Casting, Decoring, Shot Blasting, and Impregnation. Ensure production processes are executed efficiently while maintaining quality standards and production schedules

2. Casting Quality & Rejection Control: Analyze casting defects, identify root causes, and implement corrective and preventive actions to minimize rejection and rework. Monitor quality trends and continuously improve casting performance through process optimization

3. Die Gating & Runner System Optimization: Design, evaluate, and optimize die gating and runner systems to improve metal flow, casting yield, and product quality. Support die modifications and process improvements for enhanced productivity.

4. Process Optimization & Productivity Improvement: Improve foundry productivity, process capability, Overall Equipment Effectiveness (OEE), and manufacturing efficiency by optimizing process parameters, reducing cycle time, and eliminating operational bottlenecks

5. Cost Optimization: Drive initiatives to reduce material consumption, improve metal recovery, optimize melting efficiency, and minimize manufacturing costs without compromising product quality. Support value engineering and waste reduction programs.

6. Technology Development & Innovation: Evaluate and recommend new foundry technologies, machinery, automation solutions, and process improvements to enhance productivity, quality, and operational efficiency. Participate in continuous improvement initiatives across foundry operations

7.New Product Development Support: Work closely with Design & Development, Tool Room, Production, and Quality teams during new product development, die trials, pilot production, and process validation. Ensure manufacturability and successful product launch.

8.Process Documentation & Compliance: Develop and maintain process standards, work instructions, SOPs, inspection parameters, and process documentation. Ensure compliance with quality systems, safety procedures, and statutory requirements.

9.Cross Functional Coordination & Team Development: Coordinate with Production, Quality, Maintenance, Tool Room, Purchase, and Engineering teams to resolve technical issues, improve foundry performance, and achieve departmental objectives. Guide operators and supervisors on best foundry practices and process controls.