Deputy General Manager (DGM) Refractory

Sarthee Consultancy; Gurugram District; On-site; INR 4,500,000 - 7,500,000; Full time

Job summary

Sarthee Consultancy seeks a senior professional to lead strategic refractory management in integrated steel plants. You will develop long-term strategies, plan lining and relining schedules for SMS units, and set SOPs and quality standards for refractory installation and maintenance.

You will monitor performance, conduct RCA for failures, evaluate new designs with R&D and suppliers, manage procurement and vendor performance, lead shutdowns and revamps, and drive cost optimization while upholding

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 long-term refractory management strategies.
• Plan lining and relining schedules for SMS units.
• Develop SOPs and quality standards for refractory installation and maintenance.
• Drive cost reduction through material and process optimization.
• Monitor refractory performance indices and wear rates.
• Conduct RCA for refractory failures and implement corrective actions.
• Evaluate new refractory designs with R&D and suppliers.
• Benchmark KPIs against industry best practices.
• Lead shutdowns, commissioning, and revamps for refractory activities.
• Collaborate with mechanical, electrical, and operations teams for seamless execution.
• Provide technical support for process improvements and new equipment trials.

Skills

Refractory management

Vendor management

Cost control

Team leadership

Safety compliance

Education

B.E./B.Tech in Ceramic, Metallurgical, Mechanical

Job description

Role & responsibilities

Key Responsibilities

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.