Deputy General Manager (DGM) Refractory

Sarthee Consultancy; Bengaluru; On-site; INR 1,500,000 - 2,100,000; Full time

Job summary

Sarthee Consultancy invites an experienced Refractory Manager to lead strategic refractory management for integrated steel plants in Bengaluru. The role focuses on life-extension programs, risk management, and cost optimization across EAF/LF/VD/CCM systems.

The candidate will oversee vendor relationships, SOP development, and safety/compliance programs while coordinating with multi-disciplinary teams to ensure reliable operations and continuous improvement.

Qualifications

• B.E./B.Tech in Ceramic, Metallurgical, Mechanical, or related engineering discipline.
• Minimum 18-22 years of experience in refractory management within integrated steel plants.
• Proven expertise in refractory operations for EAF, LF, VD, CCM, Ladles, and Tundish systems.
• Significant experience in vendor management, cost control, and performance optimization.

Responsibilities

• Develop and execute long-term refractory management strategies aligned with production and cost objectives.
• Plan and manage refractory lining and relining schedules for all SMS units.
• Develop and enforce SOPs and quality standards for refractory installation and maintenance.
• Drive cost reduction through material and process optimization.
• Lead refractory activities during shutdowns, commissioning, and revamps.
• Collaborate with mechanical, electrical, and operations teams.
• Ensure safety and ISO compliance in refractory handling and maintenance.
• Prepare reports and manage refractory dashboards and histories.

Skills

Leadership

Team management

Cost optimization

Vendor management

Safety compliance

Education

B.E./B.Tech in Ceramic, Metallurgical, Mechanical, or related engineering discipline

Job description

Role & responsibilities

Key Responsibilities

1. Strategic Refractory Management
   

• Develop and execute long-term refractory management strategies aligned with production and cost objectives.
• Plan and manage refractory lining and relining schedules for all SMS units.
• Develop and enforce Standard Operating Procedures (SOPs) and quality standards for refractory installation and maintenance.
• Drive initiatives for import substitution, life enhancement, and cost reduction through material and process optimization.

Performance Monitoring and Optimization

• Monitor refractory performance indices such as life, wear rate, and consumption across SMS units.
• Analyze process parameters including slag chemistry and metal temperature to assess impact on refractory wear.
• Conduct Root Cause Analysis (RCA) for refractory failures and implement corrective actions.
• Evaluate new refractory designs and materials through trials and collaborate with Research & Development and suppliers.
• Benchmark refractory KPIs against industry best practices to ensure continuous improvement.

Material Planning, Procurement & Vendor Management

• Prepare annual refractory consumption forecasts and budgets based on production plans.
• Finalize technical specifications and lead procurement activities in collaboration with the purchasing department.
• Evaluate, qualify, and review performance of refractory suppliers and contractors.
• Monitor inventory levels to ensure optimal stock, avoiding shortages or overstocking.
• Review and approve inspection reports for refractory materials prior to usage.

Project Execution & Technical Support

• Lead refractory activities during shutdowns, commissioning, and revamps to ensure timely and efficient operations.
• Supervise refractory installation works in furnaces, ladles, tundishes, and CCMs, ensuring compliance with design specs.
• Collaborate with mechanical, electrical, and operations teams for seamless refractory-related activities.
• Provide technical support for process improvements, design revisions, and new equipment trials.

Cost Control & Optimization

• Drive refractory cost management programs to optimize expenditures per ton of liquid steel.
• Analyze cost trends; pursue local sourcing, material substitution, and efficiency improvements.
• Prepare and review refractory cost reports against budgetary targets regularly.

Safety & Quality Compliance

• Enforce strict compliance with safety procedures during refractory handling, installation, and hot repairs.
• Conduct safety audits, risk assessments, and toolbox meetings for refractory teams and contractors.
• Ensure stringent quality assurance for refractory materials and installation practices meeting technical standards.
• Promote adherence to 5S, ISO 9001, ISO 14001, and ISO 45001 management systems.
• Manage safe disposal and recycling of used refractory materials adhering to environmental norms.

Documentation, Analysis & Reporting

• Approve daily refractory performance and consumption reports.
• Maintain life cycle charts, refractory dashboards, and equipment-wise refractory histories.
• Prepare management reports, presentations, and budget variance analyses.
• Support technical audits, ISO documentation, and management review meetings.

Leadership & Team Development

• Lead and mentor a multidisciplinary team of managers, engineers, and supervisors.
• Define KPIs and performance expectations for team members.
• Drive training and skill development in refractory technology and safety practices.
• Foster innovation, accountability, and continuous learning within the refractory team.
• Manage contractors and maintain discipline and productivity in workforce deployment.

Preferred candidate profile

Qualifications and Experience

• B.E./B.Tech in Ceramic, Metallurgical, Mechanical, or related engineering discipline.

• Minimum 18-22 years of experience in refractory management within integrated steel plants.
• Proven expertise in refractory operations for EAF, LF, VD, CCM, Ladles, and Tundish systems.
• Significant experience in vendor management, cost control, and performance optimization.