AGM/DGM Continuous Casting Machine (CCM) Operation

Sarthee Consultancy; India; On-site; INR 3,500,000 - 7,000,000; Full time

Job summary

Sarthee Consultancy is seeking a senior CCM operations leader to oversee safe, efficient casting of billets and blooms. The role requires coordinating with EAF, LRF, VD, and Rolling Mill units to maintain synchronized heat arrivals and minimize delays.

You will drive production plans, improve surface and internal quality, and lead a team across maintenance, QC and R&D. The ideal candidate brings extensive CCM experience in integrated steel plants, with strong skills in Kaizen, Six Sigma and

Qualifications

• BE/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.

Responsibilities

• Lead and manage CCM operations for safe, defect-free casting.
• Plan casting schedules with EAF, LRF, VD, and Rolling Mill to align heat arrival.
• Develop and implement monthly and annual production plans.
• Optimize mold level control and cooling to improve quality.
• Review data and drive corrective actions with QC and R&D.
• Standardize SOPs for casting and sequence management.
• Ensure reliability of CCM equipment and maintenance planning.
• Monitor safety protocols and conduct safety audits.
• Lead Kaizen and Six Sigma initiatives and cost optimization.
• Mentor and develop a team of managers, engineers, and operators.
• Conduct daily/monthly performance reviews and MIS reporting.
• Collaborate with OEMs for performance improvements.

Skills

Leadership

Safety Management

Kaizen

Six Sigma

Team Development

Process Improvement

Project Management

Data Analysis

Automation Ideas

Education

BE/B.Tech in Metallurgical

Mechanical Engineering

Production Engineering

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.