ACCOUNT ASSISTANT-ESSESS

External Job Description

Role Description

Responsible for managing day-to-day foundry operations in faucet/CP fitting production. This involves overseeing melting, mould preparation, pouring, fettling, and ensuring adherence to quality, safety, and productivity standards. The Executive will coordinate with production, maintenance, and quality teams to ensure defect-free castings, optimize process parameters, reduce rejections, and maintain cost efficiency while meeting production targets.

Primary Responsibilities

Production & Process Management

• Oversee daily foundry operations including melting, mould preparation, pouring, fettling, and inspection.
• Ensure adherence to casting process parameters (temperature, pouring rate, sand/chemical composition, etc.).
• Plan and monitor production schedules to meet casting targets with minimal delays.
• Maintain strict control over metal charging practice (brass, zinc alloys, additives) to achieve required compositions.
• Supervise moulding sand preparation, testing, and control (moisture, permeability, strength).
• Ensure proper mould/core handling to avoid breakage and dimensional defects.
• Optimize fettling and finishing operations to reduce cycle time and improve surface finish.

Quality Assurance & Problem Solving

• Work with Quality team to reduce casting defects such as porosity, shrinkage, cold shuts, and blowholes.
• Conduct root cause analysis for casting rejections and implement corrective/preventive actions.
• Regularly check casting dimensional accuracy and surface finish against drawings/specifications.
• Maintain process documentation and quality records for audits and certifications (ISO/IS standards).
• Support new product development trials by preparing prototype castings.

Equipment, Tooling & Maintenance

• Monitor and maintain pattern, core box, and die conditions to ensure dimensional accuracy of castings.
• Coordinate with maintenance team to ensure uptime of melting furnaces, moulding machines, and fettling equipment.
• Work closely with tooling/design team for pattern modifications to improve castability.

Resource & Cost Optimization

• Track consumption of raw materials, fluxes, chemicals, and fuels, ensuring optimal usage and minimal wastage.
• Monitor yield and metal recovery percentages, suggesting process improvements for cost savings.
• Monitor foundry consumables inventory and coordinate with purchase/stores for timely availability.

Reporting & People Management

• Prepare and present daily/weekly/monthly performance reports (production, rejection, cost)
• Train and guide shop-floor operators/workers on best casting practices and safety norms.
• Conduct daily review meetings with operators for problem-solving and performance tracking.

People Management - Off role manpower (5-10)