Heavy casting engineer

Heavy Casting & Machining

• Handle machining of heavy and critical cast components used in engineering and industrial applications.
• Understand casting characteristics, machining allowances, defects and their impact on machining.
• Coordinate with Foundry, Quality, Production and Machine Shop teams for smooth production.
• Review casting drawings, machining drawings and technical specifications.
• Ensure proper identification, handling and traceability of heavy cast components.

2. CNC / VMC / HMC Operations

• Strong practical knowledge of CNC, VMC and HMC machining operations.
• Plan machining processes for heavy and complex components.
• Understand machine capabilities, work envelope, spindle capacity, tooling requirements and cutting parameters.
• Monitor CNC/VMC/HMC machine performance and productivity.
• Support CNC program selection, prove-out, setting and process optimization.
• Knowledge of G-code/M-code and basic CNC programming will be an advantage.
• Optimize cutting speed, feed, depth of cut and tooling to improve productivity and tool life.

3. Machine Shop Process Planning

• Prepare machining process plans and operation sequences.
• Determine suitable machines, fixtures, tools and gauges for different components.
• Develop and implement efficient machining methods for new and existing components.
• Reduce setup time, cycle time, rejection and rework.
• Coordinate with Tool Room/Tooling team for suitable cutting tools and fixtures.

4. Drawing & Technical Knowledge

• Read and interpret engineering drawings, machining drawings and GD&T.
• Understand dimensional tolerances, surface finish, datum systems and geometric tolerances.
• Verify critical dimensions during and after machining.
• Identify machining-related issues and provide technical solutions.

5. Quality Control

• Ensure machined components meet drawing and customer requirements.
• Coordinate with Quality/Inspection teams for dimensional inspection.
• Handle machining deviations, rejection, rework and corrective actions.
• Conduct root-cause analysis for recurring machining defects.
• Ensure proper use of measuring instruments such as Vernier, Micrometer, Bore Gauge, Height Gauge, Dial Gauge, etc.

6. Production & Productivity

• Achieve daily/monthly production targets.
• Monitor machine utilization, productivity and cycle time.
• Plan manpower and machine allocation according to production requirements.
• Monitor downtime and coordinate with Maintenance for machine-related issues.
• Maintain production and machining records.
• Implement 5S, Kaizen, Lean Manufacturing and continuous improvement initiatives.

7. Foundry Coordination

• Coordinate with Foundry/Pattern/Quality teams regarding casting issues affecting machining.
• Review casting defects such as blow holes, shrinkage, sand inclusion, misrun, mismatch and dimensional variation.
• Provide feedback to Foundry for improving casting quality and machining allowance.
• Ensure smooth movement of components from casting to shot blasting, fettling, machining and final inspection.

Required Technical Skills

• Strong knowledge of Heavy Casting / Heavy Engineering components.
• Hands-on knowledge of CNC machines.
• Strong knowledge of VMC Vertical Machining Centre.
• Strong knowledge of HMC – Horizontal Machining Centre.
• CNC machining process planning.
• CNC setting and machine operation knowledge.
• Basic knowledge of CNC programming, G-code/M-code.
• Tool selection and cutting parameter optimization.
• Fixture and work-holding knowledge.
• Engineering drawing and GD&T knowledge.
• Knowledge of measuring instruments and dimensional inspection.
• Knowledge of machining defects and troubleshooting.
• Knowledge of production planning and process improvement.
• Knowledge of 5S, Kaizen, Lean Manufacturing and TPM will be an advantage.Role & responsibilities

Preferred candidate profile

Perks and benefits