Sr. Foundry Enginer

Sr. Foundry Design & Development Engineer.

Ensure Quality and Delivery, Manage People and Skill Development, Drive Growth, Enjoy Teamwork and Team Building.

Independently develop foundry tooling and casting processes, from customer drawing review and feasibility assessment through design, simulation, trials and production release.

Department:

Engineering

Reporting to:

Engineering Head

Direct Reportees:

To be defined

Qualification:

Diploma / BE / B.Tech in Mechanical, Metallurgical or Production Engineering

Experience:

8-10 years of relevant foundry design and development experience

Employment Type:

Full-time

No of Vacancy:

To be confirmed

Salary:

Based on experience and capability

Key Accountabilities -

1    Tooling and Process Development: Independently develop foundry tooling and casting processes, from customer drawing review and feasibility assessment through design, simulation, trials and production release.

2    Reliable Processes: Establish reliable processes that meet quality, cost and productivity requirements.

3    NPD and Existing Castings: Support new-product development and improvements to existing castings.

The role you will play

Feasibility and Development

•    Review customer drawings, material specifications and critical requirements.

•    Assess castability, machining allowances and manufacturing risks.

•    Provide technical inputs for quotations and development planning.

Tooling Design

•    Design dies, patterns, cores, core boxes and tooling assemblies.

•    Prepare 3D models, detailed manufacturing drawings, bills of materials and tooling specifications.

Casting Process and Methoding

•    Define suitable production methods, equipment, process sequences and operating parameters.

•    Develop gating, feeding and rise ring systems where applicable, with particular attention to vertical centrifugal casting processes.

Casting Simulation

•    Use simulation software to evaluate filling and solidification, identify potential defects and optimise tooling and process designs before trials.

Tooling Manufacture and Trials

•    Coordinate with internal teams and tooling suppliers to ensure tooling readiness.

•    Lead casting trials, analyse results and implement corrections until the process is ready for production.

Production Handover

•    Establish validated process parameters, process sheets, work instructions and acceptance criteria with Production and Quality.

•    Train the shop-floor team on new or revised processes.

Continuous Improvement

•    Investigate casting defects and implement engineering improvements to reduce rejection, improve yield and cycle time, and increase tooling life.

Engineering Documentation

•    Maintain design revisions, engineering change records, trial reports and tooling maintenance requirements.

•    Ensure approved product and process data are available in the manufacturing engineering system.

Expected Outcomes (KPI's) -

•    Timely completion of tooling and new-product development milestones

•    Successful casting trials and stable production handover

•    Reduction in casting rejection and repeat defects

•    Improvement in casting yield, cycle time, tooling life and manufacturing cost

•    Accuracy and completeness of engineering documentation

Required Skills and Experience

•    8-10 years of hands-on experience in foundry tooling design, casting methoding and process development.

•    Proficiency in 3D CAD modelling and detailed engineering drawings.

•    Hands-on proficiency in casting simulation software, with the ability to set up studies, interpret results and translate findings into practical design changes.

•    Strong understanding of casting defects, solidification, dimensional control and tooling manufacture.

•    Ability to independently manage development activities and work closely with Production, Quality, Machining and tooling suppliers.

•    Previous experience in shell moulding and investment casting is preferred.

•    Experience in SG/grey iron and centrifugal casting will be an added advantage.