Smelting Furnace Manager

• Lead and manage smelting furnace operations, including charge preparation, melting, refining, tapping, and casting, with a strong focus on process optimization, metallurgical control, and safety to ensure efficient and high-quality production of non-ferrous metals and alloys.
  
• Oversee the day-to-day operation of smelting furnaces (reverberatory, rotary, induction, or electric arc) for optimal metal extraction.
  
• Ensure strict adherence to Standard Operating Procedures (SOPs), process parameters, and safety norms.
  
• Monitor temperature profiles, feed rates, slag composition, and metal recovery efficiency.
  
• Maintain metallurgical control over reduction, oxidation, and refining stages.
  

• Plan and execute monthly and daily production targets in coordination with production planning teams.
  
• Drive process improvements to increase furnace throughput, yield, and reduce specific energy consumption.
  
• Ensure maximum furnace availability through efficient refractory life management and preventive shutdowns.
  

• Ensure consistent product quality as per BIS / ASTM / customer specifications.
  
• Liaise with the quality control laboratory to ensure real-time chemical and physical testing of inputs and outputs.
  
• Minimize impurity carryover and control trace elements in the final metal.
  

• Coordinate with the maintenance team for routine and preventive maintenance of furnace equipment (burners, electrodes, blowers, cooling systems).
  
• Review equipment health indicators and lead root cause analysis (RCA) of breakdowns.
  
• Support automation and digital maintenance tools like DCS, SCADA, or predictive systems.
  

• Enforce safety protocols across the smelter area, including PPE usage, hot work permits, confined space entries, etc.
  
• Lead safety toolbox talks and participate in hazard identification and risk assessment (HIRA).
  
• Ensure all emissions, effluents, and waste (slag, fumes) meet environmental compliance norms.
  

• Lead a team of furnace operators, shift in-charges, and technicians; provide on-the-job training and mentoring.
  
• Conduct performance reviews, skill mapping, and promote a culture of discipline and continuous improvement.
  
• Coordinate with HR for manpower planning, shift rosters, and competency development.
  

• Monitor and control consumption of key consumables like fluxes, refractories, fuel, electrodes, etc.
  
• Implement cost-saving initiatives and benchmarking practices from industry leaders.
  
• Work closely with the stores and procurement department for the timely availability of materials.
  

• Prepare daily, weekly, and monthly furnace performance reports including downtime, output, efficiency, and deviations.
  
• Support internal and external audits, inspections, and statutory reporting (e.g, Factory Act, Pollution Board, etc.)
  

• Education: B.E./B.Tech in Metallurgy / Mechanical / Chemical Engineering
  
• Experience: Minimum 10+ years in Smelting Operations (preferably in non-ferrous metals like Lead, Zinc, Aluminium, Copper)
  
• Skills:
  
• Strong knowledge of smelting thermodynamics and furnace design
  
• Familiarity with lean manufacturing, TPM, and Six Sigma principles
  
• Proficiency in ERP systems (SAP) and automation tools
  

Job Types: Full-time, Permanent

Pay: ₹50,000.00 - ₹80,000.00 per month

Work Location: In person