AGM/DGM Continuous Casting Machine (CCM) Operation

Sarthee Consultancy; Hyderabad; On-site; INR 2,500,000 - 4,500,000; Full time

Job summary

Sarthee Consultancy seeks a seasoned CCM Operations Leader to oversee the casting of billets and blooms in a large steelmaking environment. You will coordinate with EAF, LRF, VD, and Rolling Mill units to ensure synchronized heats and minimal delays, while targeting monthly and annual tonnage goals.

You will champion improvements in mold control, cooling, and withdrawal parameters, and lead Kaizen and Six Sigma projects to optimize costs and quality.

Qualifications

• Extensive experience in CCM operations in integrated steel plants.
• Proven ability to plan casting schedules and coordinate with EAF, LRF, VD, and Rolling Mills.
• Implement Kaizen, Six Sigma, and cost-optimization projects.
• Lead safety, quality, and environmental compliance in a heavy manufacturing setting.

Responsibilities

• Lead and manage CCM operations for continuous, safe, defect-free casting of billets and blooms.
• Plan casting schedules with multiple units to ensure heat arrival synchronization and minimize delays.
• Develop production plans to meet monthly and annual tonnage goals.
• Drive process improvements in mold level control, cooling, withdrawal speed, and oscillation for quality gains.
• Oversee maintenance planning with mechanical, electrical, and instrumentation teams.

Skills

Leadership

Strategic planning

Continuous improvement

Kaizen/Six Sigma

Root cause analysis

Safety compliance

Team mentoring

Maintenance planning

Education

BE/BTech in Metallurgical/Mechanical/Production Engineering

Tools

Automation & digitization

OEM collaboration (Danieli/SMS/Primetals)

Job description

Role & responsibilities

Key Responsibilities

• Lead and manage all CCM operations, ensuring continuous, safe, and defect-free casting of billets and blooms.
• Plan and execute casting schedules in coordination with EAF, LRF, VD, and Rolling Mill units to ensure heat arrival synchronization and sequence continuity, minimizing delays and metal loss.
• Develop and implement production plans targeting monthly and annual tonnage goals.
• Optimize mold level control, secondary cooling, withdrawal speed, and oscillation to enhance surface and internal quality.
• Review casting data and defect reports; implement corrective actions and collaborate with Quality Control and R&D teams on process improvements.
• Standardize and enforce operating procedures (SOPs) for casting, tundish preparation, and sequence management.
• Ensure high mechanical and electrical reliability of CCM machines, including molds, tundish cars, torch cutting, hydraulic systems, and secondary cooling equipment.
• Plan and monitor preventive, predictive, and breakdown maintenance activities with Mechanical, Electrical, and Instrumentation departments.
• Approve maintenance schedules, equipment overhauls, and major repairs; review downtime and feedback reports.
• Manage inventory and availability of critical spares and consumables such as molds, SENs, tundish refractories, and rollers.
• Enforce strict compliance with safety protocols, PPE usage, and SMS safety standards.
• Lead safety audits, risk assessments, and incident investigations within the CCM area.
• Ensure compliance with environmental regulations related to fume extraction, water discharge, and dust suppression.
• Promote 5S, housekeeping, and continuous safety training.
• Monitor KPIs including yield, productivity, sequence length, downtime, and lead improvement activities.
• Conduct daily and monthly performance reviews with operations and maintenance teams.
• Analyze trends and prepare MIS reports for senior management presentations.
• Identify opportunities for automation, digitization, and technological upgrades.
• Collaborate with OEMs such as Danieli, SMS, Primetals for performance improvements and technical modifications.
• Lead root cause analysis for major casting failures, breakouts, and nozzle blockages.
• Initiate and implement Kaizen, Six Sigma, and cost optimization projects.
• Lead, mentor, and develop a team of managers, engineers, and operators.
• Manage shift operations, manpower utilization, and skill matrix implementation.
• Conduct training on casting technology, safety, and problem-solving techniques.
• Foster a culture of accountability, teamwork, and innovation.

Preferred candidate profile

Qualifications & Experience

• B.E./B.Tech in Metallurgical, Mechanical, Production Engineering or related field.
• AGM: 16 to 20 years of integrated steel plant experience in CCM operations.
• DGM: 20 to 25 years of experience with leadership and technical expertise in billet/bloom casting operations.