Locations : - Ahmedabad, Bharuch, Surat, Pune
Department/Unit:
CCR Operations
Reporting To:
Head of Operations & Maintenance (O&M)
Direct Reports:
CCR Shift In-charges, CCR Process Engineer (if separate from central process engineering)

Job Purpose/Summary:

To lead and manage all operational aspects of the Continuous Cast Rod (CCR) unit, ensuring the safe, efficient, and compliant production of high-quality copper rods/wire rods. This role is responsible for optimizing the casting process, achieving production targets, and maintaining product specifications.

Key Responsibilities & Duties

Operational Management:
Oversee daily CCR operations, including melting, holding, continuous casting, cooling, and coiling, to meet production schedules and precise dimensional/quality specifications.
Process Optimization:
Continuously monitor and analyze casting parameters (e.g., melt temperature, casting speed, cooling rates) to optimize efficiency, minimize scrap, and improve rod quality.
Production Planning:
Work with O&M Head to develop and implement daily, weekly, and monthly production plans for the CCR unit.
Safety & Environment:
Ensure strict adherence to all safety protocols (especially related to molten metal and high temperatures), environmental regulations, and waste management procedures within the CCR.
Quality Control:
Collaborate with the Quality Control department to ensure copper rods meet stringent quality specifications (e.g., diameter, surface finish, conductivity) and resolve any quality deviations.
Resource Management:
Optimize consumption of energy, cooling water, and casting consumables (dies, graphite). Manage manpower and equipment effectively within the CCR.
Troubleshooting:
Lead the identification and resolution of complex operational issues, machine malfunctions, and process upsets (e.g., rod breaks, surface defects).
Team Leadership:
Lead, mentor, and develop CCR Shift In-charges and other operational staff. Foster a culture of continuous improvement and operational discipline.
Maintenance Coordination:
Liaise closely with the Maintenance team for planning and execution of CCR equipment maintenance, die changes, and overhauls.
Reporting:
Prepare comprehensive operational reports, analyze performance data, and present findings and recommendations to the O&M Head.

Key Performance Indicators (KPIs):

Copper Rod Production Volume (Tons/Month)
Rod Quality (Dimensional Tolerance, Surface Defects, Conductivity)
Scrap Rate (%)
CCR Unit Downtime (Planned vs. Unplanned)
Energy Consumption per Ton of Rod
Safety Incidents in CCR
Adherence to Casting Parameters

Required Qualifications:

Bachelor's degree in Metallurgical, Mechanical, or Materials Engineering.

Required Experience:

15+ years of experience in continuous casting operations, preferably in non-ferrous metals, with at least 5-7 years in a leadership/managerial role within a CCR plant.
Extensive knowledge of various CCR technologies (e.g., Properzi, Upcast, vertical/horizontal casting).

Required Skills:

In-depth knowledge of
continuous casting principles, metallurgy of copper
, and rod rolling.
Strong
leadership, analytical, and problem-solving
Excellent
decision-making
abilities, especially under pressure.
Proficiency in
process optimization
Solid understanding of industrial
safety regulations
(especially molten metal handling).
Effective
communication
and interpersonal skills.

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